bent sway bar?

mlwarriner · Posted: Sat Mar 17, 2012 8:15 pm Post subject: bent sway bar?

a couple of weeks ago, i replaced the end links and end link bushings on my sway bar with the links and power flex bushings from t3 technique. everything seemed to go back together well enough, but this weekend, after only a few miles of driving, i rolled in underneath my van to find that one end of the sway bar had popped out of the upper end of the drop link, bushing and all.

is my sway bar bent/tweaked, or is there something else amiss?

please and thanks.

windnsea · Posted: Sat Mar 17, 2012 8:26 pm Post subject:

In all probability it's an alignment problem. Harder bushings but more stress on the connection and if the alignment is not perfect, things do pop. Is the sway bar centered in it's two brackets?

mlwarriner · Posted: Sat Mar 17, 2012 8:28 pm Post subject:

based on the grimy vs. clean spots on the bar, it's right back where it was before. whether that's perfectly centered or not i can't say...

IdahoDoug · Posted: Sat Mar 17, 2012 9:48 pm Post subject:

ML - what vehicle type and year?

DougM
_________________
Two fully locked 80 Series LandCruisers. 2013 Subaru Impreza boxer. 1990 Audi 90 Quattro 20V

mlwarriner · Posted: Sat Mar 17, 2012 10:11 pm Post subject:

IdahoDoug · Posted: Sat Mar 17, 2012 10:21 pm Post subject:

I asked because different years and models have thicker or thinner bars. If yours has the thinner bars (I think it does - others should chime in) it may come out of the bushing more easily. Or it may be the new bushing is sized for all bars and doesn't work with yours. Dunno.

However, I will state categorically that your sway bar is not bent unless it has been in an accident of epic proportions. Sway bars have to take thousands of pounds of rotating lbs-ft and are made of an incredibly tough steel. So odds are that the bar itself is fine. Check for centering as suggested, though the bar can self center as the bushings attaching it to the frame/floor allow for lateral movement.

How hard were they to insert the bar ends in? If they were not much of a fight you may have a clue. Any lift or non stock springs on your vehicle? Or non stock shocks that allow the suspension to move farther than originally designed?

DougM
_________________
Two fully locked 80 Series LandCruisers. 2013 Subaru Impreza boxer. 1990 Audi 90 Quattro 20V

mlwarriner · Posted: Sun Mar 18, 2012 5:53 am Post subject:

Christopher Schimke · Posted: Sun Mar 18, 2012 5:56 am Post subject:

I have one other customer who had this issue. Please check your bar diameter first, but if that does not seem to be the problem, let me know and I will send you a new bushing to try.
_________________
Christopher

*Custom wheel hardware for Audi/VW and Mercedes wheels - Urethane Suspension Bushings*
T3Technique.com or contact me at [email protected]

Williamtaylor33 · Posted: Sun Mar 18, 2012 6:21 am Post subject:

THis happened to me too. But it was in a syncro and offroading. It seems at full droop of the front suspension it popped off. I was able to get it back on and it hasn't happened since.
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89 syncro westy
SS Radius arm and drop link sleeves for sale..

insyncro · Posted: Sun Mar 18, 2012 7:06 am Post subject:

BillM · Posted: Sun Mar 18, 2012 7:14 am Post subject:

One thing to keep in mind when doing any work on the sway bars.
It's must be sitting on the ground with all four tires and only then
should you tighten all the fastners. If you do this while on a lift or jack
you will be preloading the bar. I'm sure you all know this already but
just a reminder.
_________________
Bill M
87 Westy
Zetec Turbo

IdahoDoug · Posted: Sun Mar 18, 2012 10:33 am Post subject:

I wouldn't sweat tightening it with the bar flexed, such as on a jack, etc. The bar is designed to freely pivot, so the bushings cannot actually restrict its movement or preload it. When the van is let down, the bar will simply pivot to its natural resting state.

I don't want the OP to think if he did that, it was his fault due to tightening up on a jack. Look elsewhere.

DougM
_________________
Two fully locked 80 Series LandCruisers. 2013 Subaru Impreza boxer. 1990 Audi 90 Quattro 20V

mlwarriner · Posted: Sun Mar 18, 2012 7:27 pm Post subject:

mlwarriner · Posted: Sun Mar 18, 2012 7:30 pm Post subject:

oh yeah. all work was done with the van up on jack stands, both wheels completely off the ground.

the left side link (the one that popped out) was broken off and the bushing sleeve was rusted in pretty hard (on what i think was factory parts). i cleaned out both sides of the bushing seats as best i could, and they seemed pretty ok.

mlwarriner · Posted: Sun Mar 18, 2012 7:45 pm Post subject:

bar is 1" diameter. i don't have the packaging from my powerflex bushings, so i can't quote you the part number i received. Sad

Christopher Schimke · Posted: Mon Mar 19, 2012 6:01 am Post subject:

Matt,

The two bar diameters will be 19mm (3/4") or 21mm (just a tick over 13/16"). I'm guessing that you have a 21mm bar. Your order included the 21mm bushings. I'll send you a new bushing to see if that cures your problem.
_________________
Christopher

*Custom wheel hardware for Audi/VW and Mercedes wheels - Urethane Suspension Bushings*
T3Technique.com or contact me at [email protected]

mlwarriner · Posted: Mon Mar 19, 2012 6:39 am Post subject:

rsxsr · Posted: Mon Mar 19, 2012 7:09 am Post subject:

A 19mm open end wrench will tell you.
_________________
1982 Diesel Vanagon Camper with ALH TDI.
1987 Syncro Tin Top. Organ Donor
2011 TDI Jetta Sportwagen.

Christopher Schimke · Posted: Mon Mar 19, 2012 7:51 am Post subject:

Well, there was a 23mm bar available, but as far as I know, none were officially sent to the US. They were for the heavy duty platforms used for Ambulances and such. However, you mentioned that the bushing wasn't all that hard to install. Trying to install a 21mm bushing onto a 23mm bar could be done, but it would be a bit of a struggle and he result would be very tight so having the endlink come off doesn't make much sense.

Without any dirt, grease, crud, etc., a 21mm bar will give you a circumference of roughly 2.6". A 23mm bar would be a circumference of 2.84".

I'm doubtful that you have a 23mm bar (the bushing popping off doesn't make sense - as described above), but I will hold of on sending a new bushing until we know for sure.
_________________
Christopher

*Custom wheel hardware for Audi/VW and Mercedes wheels - Urethane Suspension Bushings*
T3Technique.com or contact me at [email protected]

mlwarriner · Posted: Mon Mar 19, 2012 2:38 pm Post subject:

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