Hellwig Front Bushing Replacement

[KFordEx8]

It didn't take long for a clunking noise to start after the front OEM bar was replaced with the Hellwig unit. Got worse as time went by.

Ordered Prothane part no. 191505 from suspension.com and replaced them today. Didn't hear any clunking with a short test drive.

The Prothane bushings are slightly larger; included metal brackets are thinner. They are also a better fit because the bracket holes are smaller.

 

[maxxplatinum9137]

It didn't take long for a clunking noise to start after the front OEM bar was replaced with the Hellwig unit. Got worse as time went by.

Ordered Prothane part no. 191505 from suspension.com and replaced them today. Didn't hear any clunking with a short test drive.

The Prothane bushings are slightly larger; included metal brackets are thinner. They are also a better fit because the bracket holes are smaller.

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Why did you get a hellwig to begin with? What are advantages over OEM?

 

[DWs-TTEB]

Why did you get a hellwig to begin with? What are advantages over OEM?

well documented in these threads:

Hellwig Sway Bars - Front and Rear - Performance Review

Removed the front & rear stock sway bars yesterday and installed a set of Hellwig’s aftermarket sway bars. This easy install sway bar modification significantly improved the handling of our Expedition EL Limited. Before this modification I truly hated driving our Expedition because it cornered...

www.expeditionforum.com

Rear Sway bar?

Has anyone installed an aftermarket rear sway bar on their 4th gen? I can't stand how much mine sways from side to side on rough country back roads. My wife nicknamed my car the "bobblehead" because it literally makes you feel like a bobblehead swaying back and forth in it on the country...

www.expeditionforum.com

 

[BMW2FORD]

The thicker tighter sway bar bushing and bracket will be better to help the cause of better handling but for sure noise can be a problem. This is a generic picture but you might have to find bushings with a grease fitting or what I’ve done on a lot of cars is drill a hole with them removed, tap it and add one.

Energy Suspension 9.5165R 1-1/4" Greasable Sway Bar Set https://www.amazon.com/dp/B000CN7C1...t_i_010GQZQN879J2R9GGVV5?_encoding=UTF8&psc=1

 

[KFordEx8]

The thicker tighter sway bar bushing and bracket will be better to help the cause of better handling but for sure noise can be a problem. This is a generic picture but you might have to find bushings with a grease fitting or what I’ve done on a lot of cars is drill a hole with them removed, tap it and add one.

Energy Suspension 9.5165R 1-1/4" Greasable Sway Bar Set https://www.amazon.com/dp/B000CN7C1...t_i_010GQZQN879J2R9GGVV5?_encoding=UTF8&psc=1

I wasn’t able to find a 1.5” with a grease fitting. When it starts squeaking and I can’t stand it, I’ll mod it with a fitting.

 

[wakeboarder]

It didn't take long for a clunking noise to start after the front OEM bar was replaced with the Hellwig unit. Got worse as time went by.

Ordered Prothane part no. 191505 from suspension.com and replaced them today. Didn't hear any clunking with a short test drive.

The Prothane bushings are slightly larger; included metal brackets are thinner. They are also a better fit because the bracket holes are smaller.

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Is the rubber split or do you have to completely remove the bar to install them?

 

[KFordEx8]

The bushings are split so just have to pull each open to slip around the bar. I used a heat gun on low to warm them up so they would spread easier. Another way is to make them more flexible is to warm them in hot water.

Went for a longer drive and noticed an improvement over the Hellwig units. I think the Hellwig bushings are softer. That along with the play that developed that caused the clunking made the front end more sloppy.

 

[TheDoug]

It didn't take long for a clunking noise to start after the front OEM bar was replaced with the Hellwig unit. Got worse as time went by.

Ordered Prothane part no. 191505 from suspension.com and replaced them today. Didn't hear any clunking with a short test drive.

The Prothane bushings are slightly larger; included metal brackets are thinner. They are also a better fit because the bracket holes are smaller.

Was the clunking noise you are describing occuring when you turned or when there was a bump im road while going straight? Thanks, i got some noise from mine and wonder if this will fix issue.

 

[5280tunage]

Was the clunking noise you are describing occuring when you turned or when there was a bump im road while going straight? Thanks, i got some noise from mine and wonder if this will fix issue.

Same, I have a small clunk when turning. Sounds more like steering vs. sway.

 

[TheDoug]

Same, I have a small clunk when turning. Sounds more like steering vs. sway.

I think mine may be related to skid plate not 100 percent lined up and tightened down then. When it gets back from dealer i will have to investigation further

Thanks for info

 

[KFordEx8]

It would clunk on uneven pavement for me. It started less than two months after the swap last year in mid-April. Then got worse over time.

 

[NukeLife]

Was the clunking noise you are describing occuring when you turned or when there was a bump im road while going straight? Thanks, i got some noise from mine and wonder if this will fix issue.

I had the same issue develop with my front Hellwig just weeks after installing it. In my case, it seemed like driving straight over uneven roads or patched potholes was when it clunked the most.

I believe you would hear it less in a turn, simply because the body lean would be applying force on the sway bar, effectively pinning it in place.

Worn out (or faulty) sway bar bushings can easily be confirmed, or refuted, as the source of your noise by taking the sway bar off and driving around. That‘s what I did. Took it off—the noise went away. Put it back on—the noise immediately came back.

Hellwig promptly sent me a new set of bushings—no questions asked, and the noise never returned.

 

[KFordEx8]

Was the replacement set exactly the same and the ones that came with the bar?

I may hit them up for a replacement set just to have around as a spare.

 

[NukeLife]

Was the replacement set exactly the same and the ones that came with the bar?

I may hit them up for a replacement set just to have around as a spare.

Yep. Looked identical to the ones that were on it. Guess they have some QC inconsistencies?

 

[WALoeIII]

I developed the clunk after about 6 months. Replaced them last month and still quiet. Thanks for the great beta, will try if clunk returns on newer batch of bushings.

 

[Going_Going_Gone]

Has anyone just reused the stock Ford bushings and brackets from their original sway bar...or even know if the bars are the same diameter? I saved all four, front and rear, in the event that the "hammer finish" paint on the Hellwig would eventually wear smooth and, if the bars are the same diameter, we could just throw the stock parts back on. The stock brackets have round, not elongated slots for the attaching bolts.

 

[maxxplatinum9137]

Has anyone just reused the stock Ford bushings and brackets from their original sway bar...or even know if the bars are the same diameter? I saved all four, front and rear, in the event that the "hammer finish" paint on the Hellwig would eventually wear smooth and, if the bars are the same diameter, we could just throw the stock parts back on. The stock brackets have round, not elongated slots for the attaching bolts.

Judging by the OPs pictures they are same thickness. But why would you want to reuse the stock hardware? What’s the benefit? That’s like taking a shower and putting your dirty soiled used underwear back on. Just get new ones

 

[Going_Going_Gone]

My stock parts had only 10K miles on them. Even slightly worn, they appear to be higher quality than the Hellwigs. In the long run, I consider it better to have then and not need them than to need them and no longer have them; plus they take up minimal space in my rollaway.

 

[KFordEx8]

The stock bar is slightly smaller in diameter than the Hellwig. I pulled the OEM bushing out to check first before getting the Prothane units. OEM brackets have a more precise fit since they the holes are not elongated and sized well. Hellwig bracket holes are elongated and larger so there isn’t as much contact with the nuts. The Prothane brackets have slimmer, elongated holes so figment is better than the Hellwig hardware.

 

[NukeLife]

My stock parts had only 10K miles on them. Even slightly worn, they appear to be higher quality than the Hellwigs. In the long run, I consider it better to have then and not need them than to need them and no longer have them; plus they take up minimal space in my rollaway.

Not the same diameter. Your OEM bushings will not work on the Hellwig bar.