• Just a reminder that you won't be able to start new posts or reply to existings posts in the Archive forum.

    This is where all the old posts go so they can still be used for reference and searched.
  • Welcome to ClassicBroncos! - You are currently viewing the forums as a GUEST. To take advantage of all the site features, please take a moment to register. It's fast, simple and absolutely free. So please join our community today!
    If you have problems registering or can't log into your account, please contact Admin.

Hellwig front swaybar install & first impressions...

xcntrk

Bronco Guru
Joined
Jan 12, 2012
Messages
2,473
Loc.
NOVA
I picked up a Hellwig front swaybar from Krawlers Edge a while back when they first came out and just recently got around to installing it. Back when I purchased, Krawlers Edge was the only available vendor but now it appears Wild Horses also carries it. Either way it's a premium (expensive) product and as far as I know the only available aftermarket complete EB swaybar kit.

As for impressions, I'd like to start with the bad then cover the good. I may seem a little negative here but the bar is certainly raised due to the premium price this product demands.



First the BAD:
Narrow mounting blocks for the D bushing straps. The kit includes these mounting blocks that insert inside the frame which you then drive threaded studs into. The width of these blocks is really narrow (maybe 1/2"?) but the width of the frame is close to 2". I would have liked a more stable (wider) mounting block within the frame.

Endlinks are too short. I purchased the 0-2.5" kit and I have exactly 2.5" of suspension lift. I ended up threading the heim joints nearly all the way out in order to fit my rig and still was unable to achieve the proper horizontal position of the swaybar. I left about 3/8" of the hiem into the endlink rod which any less and I'd be worried it would snap.

Poor packaging - missing bolts and incorrect size swaybar lock ring. The kit says it supplies replacement extended bolts to replace the stock ones for the lower spring plate due to the additional thickness introduced by the lower endlink mounts. My hardware bag only had 2 when 4 are required. Also I spent 30-minutes cursing and spewing fire trying to get the swaybar lock ring to fit the bar. It wasn't until I grabbed the other one did I realize that I had 1 properly sized ring, and 1 incorrectly sized ring (too small). This really left a bad impression on me as I currently only have 1 lock ring in place and will likely have to fight with Hellwig on Monday for another of proper size.

The kit uses what appears to be nickel coated grade-5 hardware. Since I had to replace the spring plate bolts away, I did so with grade-8 zinc coated HW. For the stresses of a suspension system I was rather disappointed to see grade-5 hardware throughout.

Endlink mounting plates misalign lower spring buckets. The kit seems to assume you're using aftermarket lower spring plates which must be flat. The stock plates are not flat on the bottom and instead contour to the spring base. The Hellwig lower endlink plates that are included in the kit assume a flat surface to mount. This puts the lower spring plate in a bit of bind as you sandwich the spring plate & endlink plate onto the radius-arm perch.

Mix of Metric and Standard hardware. This isn't really a negative, just weird and a little sad (for an American product being installed on an American classic car with 100% standard hardware - until now).

Poor instructions. The instructions make multiple references to the pictures, however the print quality is poor and therefore the pictures are hard to see. This leaves you with a lot of squinting and head scratching.



Now for the GOOD:
High quality parts. Nice heim joints, thick plate that's bent not welded, and all steel parts are powder coated very well.

Massive swaybar. I don't know the size but it's probably the thickest swaybar I've ever messed with.

Ingenious disconnect system which swings out of the way.

Nice bushings and quality lubricant.

Really nice end-link design. Usually the end-links in a kit like this would be puny, but these are nice quality pieces.



IMPRESSIONS:
The swaybar performs really great and has an immediately noticeable improvement. It basically feels like you're running a much stiffer front spring, only without the adverse impact to ride quality. When cornering the whole ride is really stiffened up yet when hitting bumps there's zero change to the travel or rigidity of your front suspension.

The disconnect system is really slick and easy enough to do with one person. The whole bar swings up out of the way when disconnected.

The tolerances of the swaybar are really well engineered. It clears the pitman arm well but is tight enough that it doesn't rub the tires.



OVERALL:
Overall I give it 7 out of 10. The product itself is high-end and warrants a better review, but it's the negative items above that are holding the score down - at least in this EB owner's opinion ;)
 
OP
OP
xcntrk

xcntrk

Bronco Guru
Joined
Jan 12, 2012
Messages
2,473
Loc.
NOVA
PICS:

The kit and its contents:

IMG_1058_zps85acfa17.jpg




Look at the size of this swaybar:

IMG_1059_zpsca42c801.jpg




Pull your springs to install lower endlink plates:

IMG_1060_zpsa8664f79.jpg




Lower endlink plates installed:

IMG_1065_zps0dd50989.jpg


IMG_1066_zps84619a17.jpg




Then mount the bar:

IMG_1069_zpsab313fbf.jpg


IMG_1067_zpsc5937542.jpg




This is the incorrectly sized lock-ring which I spent 30 minutes trying to "make fit":

IMG_1073_zpsc1a20bc5.jpg




Checking steering clearance:

IMG_1080_zps12f16b77.jpg




Tire clearance - close but no prob:

IMG_1077_zps7bdd3d24.jpg




Finished product:

IMG_1082_zps89e963cc.jpg




Left overs? I don't even know what these weird rubber boots are. I think my parts bag was assembled by a child...

IMG_1084_zpsed8d4e9c.jpg
 

Hank_

Bronco Guru
Joined
May 9, 2010
Messages
1,915
Nice write up on the kit. I plan on running one of these (if I ever finish my bronco). Glad it does the job on reducing body roll. When the sway bar is disconnected and you swing it out of the way is there an attachment system to keep the bar from falling down? Thanks for taking the time to take the pics.

Henry
 

TwoDalesDad

Bronco Guru
Joined
Jul 19, 2011
Messages
1,515
I too think you did a great job on the write up. I believe you did probably better than myself when it came to mis matched bolts, snap rings etc. I have two questions....did the kit arrive with a sufficient quanity of lubricants? You did not mention the price.....Sirs..A Kings Ransome will make your pony handle..Right now I thnk the sway bar would be in the way....since my stacks of parts waiting to be used are....well standing on thier own....lol
 

ILikeBond

Sr. Member
Joined
Jan 27, 2009
Messages
908
Thanks for the review, xcntrk. I've been debating adding this to my build sheet and your review and installation write-up are both very helpful. Hopefully the manufacturer improves the hardware kit after receiving complaints if this is common.
 

willtel

Sr. Member
Joined
Oct 3, 2003
Messages
594
Are those rubber boots supposed to go over the heim joints to keep grit out of them?
 

jlylec

Sr. Member
Joined
Jul 5, 2012
Messages
891
great write-up xcntrk! it would be great to have a write-up like this on every major aftermarket part available!
 
OP
OP
xcntrk

xcntrk

Bronco Guru
Joined
Jan 12, 2012
Messages
2,473
Loc.
NOVA
did the kit arrive with a sufficient quanity of lubricants? You did not mention the price.....Sirs..A Kings Ransome will make your pony handle..

The kit came with 3 little tubes of bushing lubricant. I generously lubed all bushings and still had an entire tube left over.

The cost is right at $500 bucks for the front w/endlinks from either vendor.



Are those rubber boots supposed to go over the heim joints to keep grit out of them?
I thought so too, but it doesn't mention anything about them in the instructions and I tried fitting them over the joints which is like shoving a square into a round hole...



When the sway bar is disconnected and you swing it out of the way is there an attachment system to keep the bar from falling down?

Somehow I missed that pic in my original post. Here it is. This is the swaybar disconnected from the front axle. The endlinks swing up 180 degrees and attach to a provided mount which holds the bar up and out of the way.


IMG_1074_zpse7ba48d5.jpg
 
OP
OP
xcntrk

xcntrk

Bronco Guru
Joined
Jan 12, 2012
Messages
2,473
Loc.
NOVA
Well I talked to Hellwig, they're going to send a new swaybar lock ring out for the incorrect one that was originally sent with the kit.

Overall I've been really getting used to the new swaybar and improvement to the handling. I've been considering getting one for the rear too, if only it were available in a disconnect version.
 

Bknaus

New Member
Joined
Feb 21, 2012
Messages
131
Loc.
Visalia, CA
I don't cruise around here too much on the forums (too busy making new sway bars and working on our EB build) so this is the first time I noticed this post. For those who don't know, I'm one of the engineers at Hellwig. Thanks to xcntrk for the write-up, both the good and the bad. Without bad you never know how to improve!

I've copied down all your advice and will go through everything and see what I can improve for you guys. The main thing I want to apologize for is missing bolts/collar clamps. We recently revamped our inventory (and replaced some of the shipping guys) and have really been working on that side of the business. I'll also check the instructions. I wrote those which takes some serious time so I obviously will want to them to be legible. We will look at everything else as well and see if there's more room for improvement.

If you or anyone else have anymore comments or questions, don't hesitate to contact me either through a PM on here or emailing me directly at bknaus@hellwigproducts.com. Thanks!
 

toddz69

Sponsor/Vendor
Bronco Guru
Joined
Nov 28, 2001
Messages
10,550
I thought so too, but it doesn't mention anything about them in the instructions and I tried fitting them over the joints which is like shoving a square into a round hole...

Yeah, those boots are for the heims. I think I'd leave them off anyway in this application. Disappointing that the end link pieces make the spring seats fit so poorly. I wonder if something like Duff's lower spring seats would help with that? I still wonder if this kit would fit with a TRO setup?

Did you have to remove your front bumper to get the bolts in there for the bushings?

Tempted to put this on my list of items to add as well. Thanks for the writeup!

Todd Z.
 
OP
OP
xcntrk

xcntrk

Bronco Guru
Joined
Jan 12, 2012
Messages
2,473
Loc.
NOVA
It's been a while since I wrote this and need to follow-up.

Hellwig support was quick to ship out the correct size replacement collar clamp. I through it on and it fit like a champ. I've been really enjoying this swaybar. It makes such a dramatic improvement over front end body roll. My search continues to try and come up with a similar system for rear - which includes an ability to disconnect for wheeling...
 
OP
OP
xcntrk

xcntrk

Bronco Guru
Joined
Jan 12, 2012
Messages
2,473
Loc.
NOVA
Disappointing that the end link pieces make the spring seats fit so poorly. I wonder if something like Duff's lower spring seats would help with that?
I'm in the process of swapping my stock Dana-30 for a new Dana-44 front axle that I've been slowly building. When I make the swap I'll be installing a set of Duff HD lower spring seats. That will give both the end-link mounting plates and the spring seat a nice flat surface to mount against the radius-arm perch.


Did you have to remove your front bumper to get the bolts in there for the bushings?
I originally criticized narrow mounting blocks for the D bushing straps. They are so narrow that it doesn't give you much material inside the frame to support the bushing mounts. After thinking about it more, it dawned on me that these were so narrow so they could be inserted into the frame via an existing access hole in the frame that's used as part of the install. For me I didn't use that hole as I have stock bumpers and there's lots of room to insert the mounting block between the horns without removing the bumper. But it dawned on me that if I had a HD off road bumper that inserted well into the frame horns, you'd either have to take it off or insert the blocks through the existing frame access hole. Which seems to explain why they are so narrow. As I mentioned previously, my directions were ineligible and it's possible this was clearly stated.
 

TTTGOWYO

Tyler T. - EB Obsessed
Joined
Sep 3, 2007
Messages
2,151
Loc.
Louisville
Great write up and nice to see the manufacturer listening to the review and making it better..
 
Top