Hellwig 7898 User Manual

559-734-7451 800-367-5480 FAX [phone]

INSTALLATION INSTRUCTIONS

Rear Stabilizer Bar

Dodge 2500 - 3500 pickup w/ 4-6” lift

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR INSTALLATION

1 2

TORQUE TABLE

BOLT SIZE: 3/8” = 20-30 ft. lbs. – 7/16” = 35-45 ft. lbs. –½” =50-70 ft. lbs. – 9/16” = 70-90 ft.lbs.

SAFETY: BEFORE STARTING YOUR INSTALLATION, BE SURE TO SET PARKING BRAKE AND CHOCK TIRES.
NOTE: TO EASE INSTALLATION AND TO PROPERLY ADJUST BAR, THE WEIGHT OF THE VEHICLE MUST BE

ON THE SUSPENSION, AS IF DRIVING DOWN THE ROAD. DO NOT RAISE VEHICLE BY FRAME.

NOTE: THIS UNIT IS DESIGNED TO MOUNT TO THE REAROF THE AXLE TUBES WITH THE ARMS OF THE BAR

TOWARD THE REAR OF THE VEHICLE. THE HUMP SHOULD TILT SLIGHTLY DOWNWARD.

NOTE: THIS KIT INCLUDES LOCK NUTS WHICH REQUIRE TIGHTENING WITH A WRENCH AFTER BEING STARTED

BY HAND.

1. As shown in photo one (1), place D-shaped poly-bushings onto straight areas of the bar on each side of center hump. After installing D­bushings onto bar, place U-plates on D-bushings.

2. Place U-bolts on axle tubes next to casting as shown in photo two (2). When installing U-bolts, be sure to put U-bolts under any

brake lines, wires or hoses on the axle to avoid any possible damage.

3. Before installing saddle brackets, reposition passenger side brake line so that it will clear the saddle bracket Place saddle brackets
on axle by inserting legs of U-bolts into the holes in saddle brackets. Saddle brackets must be installed so that one leg of the saddle
bracket is located on the cast center section with the leg just inside the raised lip on the casting. See photo two (2)

4. Raise bar and place D-bushings on saddle brackets by inserting legs of U-bolts through holes in U-plates. Install flat washers and hex
nuts provided on U-bolts. Do not use locknuts provided in kit on axle U-bolts. LEAVELOOSEAT THIS TIME to allow for
adjustment later.

5. Locate existing spare tire crossmember on vehicle frame. Place square U-bolt over frame rail just behind crossmember with legs of U­bolt pointing downward. See photo (1).

6. Insert legs of U-bolt into slotted holes of the hanger brackets. Install hanger brackets with clevis inboard of frame rail and toward front
of vehicle as shown in photo three (3). Attach using 1/2” lock nuts. LEAVE LOOSE for adjustment later.

7. Attach clevis to end of sway bar with 1/2 x1-1/2” bolt, thick washer and locknut as shown in photo (3).. Torque to 50 ft-lb.

7895(R-7895) 02/17/09

559-734-7451 800-367-5480 FAX [phone]

9/16” Jam Nut

7/16 X 2-1/4” Bolt

Clevis

1/2 X 1-1/2” Bolt

7. Assemble end links as shown in photos with 9/16” nut on the threaded half. Leave loose for adjustment. Insert hourglass bushing first

and then sleeve into the loops of the end link assembly. Lubricate the bushing and sleeve to ease assembly

8. Attach clevis on sway bar to end link using 7/16 X 2-1/4” bolts and locknuts provided in kit. LEAVE LOOSE AT THIS TIME to allow

for adjustment later.

3

9. With sway bar loosely mounted, work bar back and forth in D-shaped poly bushings to center bar.

10. Tighten frame bracket U-bolts to 50 ft-lb..

11. Tighten end link clevis bolts to 35 ft-lb.

12. Tighten jam nut on end link to lock into place.

13. Tighten axle U-bolts to 60 ft-lb. Place second nut on U-bolt and tighten against primary nut to lock in place.

14. Recheck your installation, looking for clearance on any undercarriage components, such as gas lines, exhaust pipes, brake lines, wiring,

differential cover, etc.

15. Drive vehicle for a few miles, then recheck for position and tightness, readjust and retorque as needed. Then recheck periodically

thereafter.

ATTENTION INSTALLER: PLEASE MAKE SURE CUSTOMER RECEIVES THIS INSTRUCTION SHEET,

7895(R-7895) 02/17/09