Hellwig Sway Bar - Bad Fit

[emaki]

After reading so much about the Hellwig sway bar. I purchased one and installed it today. I am very disappointed.

The install looked so close to the shock mount on the passenger side of the axle, that I did a little test. I put the left rear tire on a sidewalk curb with the right rear on the pavement...and it hits. With 6 inches of suspension travel on the driver side, the passenger side of the sway bar hits the shock mount on the axle.

This sway bar is installed as over to the left side (driver) as I can get it, and it still hits. End link by the gas tank is dead vertical. End link on the passenger side has what looks like 5 degrees of positive camber (end link at the bottom is closer to vehicle center than the top of the end link).

Even the axle bracket bowed out at a torque of 45 lb/ft. The Tundra really can benefit from a little more rear sway control, but this thing is a piece of junk. I need to call these guys Monday. Anybody else had this problem? My first reactions are that this thing is of low build quality and not suited to even the mildest off-road condition. Box says PN-7641, which is for the Tundra. I have the fancy quick disconnect end links on order, but I don't even know how well they will fit given the angle on the right side end link.

I posted photos onto my photo gallery. That's a first for me. I wonder how I can get them to show?

[tempetom]

I've heard several others post that their Hellwig wasn't the right size. Hellwig sent someone a new one awhile back. If you want to you can measure yours at key points and I or someone else would be glad to compare.

I don't think the sway bar is for off roading, but that doesn't sound like part of your problem.

[H2O_MAN]

Originally Posted by emaki

After reading so much about the Hellwig sway bar. I purchased one and installed it today. I am very disappointed.

Without seeing your installation I suggest you read this article - it may help you find a solution.

If you make it to the Athens area I would be happy to meet you and check it out.

[Invid]

I concur with the above statement about not being able to see your installation. I put my Hellwig on in the winter of 2004 and I just love it. The fit is perfect and I haven't had any problems with it touching anything. I've had to tightend the frame nuts once since I've put it on but that's it.

Post some pics if you could.

[KAELA]

Is your truck an Access or Double Cab???

[Invid]

Zoom out on your images so I can see the larger picture. Your install looks wrong to me like it was installed incorrectly or is for another vehicle type. The pictures focus on the intersections, now let's see the whole thing.

[mokeiko]

I had the same problem also. I made a couple of shims 1/8 inch thick from a flat piece of metal bar I purchased and that seemed to help with the clearance problems of the Hellwig bar hitting the rear right passenger shock mount.

http://home.hawaii.rr.com/pouncy/Hellwig.jpg

[cupidstoy]

mine centered up ok on a DC, but it took a little work. be sure to grease the D-gaskets to keep them form squeeking. i've got about 15,000 miles on mine no problems. i agree with others that you might have received the wrong application for your truck or have a defective product.

[tempetom]

H20_man,
I happened to see the "after" photo in the link you posted. I had installed mine that way and after about 6 months use, it shifted to one side. I could tell it did since the grease was in the original position. I ended up moving the U-bolts both outboard a little yesterday. Where I have em now, they shouldn't be able to shift much. I'll take a photo of it tomorrow and post it. Here's the photo I was referring to in the link:

[tempetom]

Ok, here's where it is now. I hope it wasn't meant to slided sideways at times. I'll keep an eye on it to see how it looks.

[yjk1975]

I think you got the wrong part. It does not look right. On my DC everything lines up straight and not in an angle.

[emaki]

Thanks guys. I think it is wrong as well. It would be darn near impossible to mount the bar wrong and even get it to fit. So I know it was installed correctly. Vehicle is a double cab. After I first posted I went for a drive and the fit got worse. Now you can just fit a quarter thin side (what is that like 1/16") between the bar and the left lower shock mount, with the truck on level ground. I called Hellwig and they are being helpful. I will send them the picture and some dimensions. I'm sure we will figure it out.

[dead mike]

I just walked in the house after installing my sway bar. It is also touching the passenger side shock mount. I have it centered dead on also. I have the box off the truck so i have a better opportunity to look things over. Its basically the same scenario as the first poster. Any ideas.

[rpm2day]

Mine fit well except that the end link spacers were too long-had to grind about 1/4" off the length.
The truck now handles very well. I'm going for poly bushings for the front bar and steering rack next. Then real shocks and tires...........
BTW I think I posted elsewhere-JC Whitney $159 and $7.00 shipping. Not too bad but you have to call for the part#. Also got my Lund Wraparound bugshield there-good price fast shipping.

[Burger Steak & Eggs]

I have installed Hellwig products on multiple vehicles and have always had to trim/bend/file due to poor fit. They need to include a selection of die grinder bits, or perhaps an acetylene torch gift certificate with every kit they sell.

The ironic part is, I will probably buy one again for my Tundra, partly because nobody else makes them for this truck, and partly because once you do get them on, they work as advertised. The handling improvement is tremendous.