front end overhaul - sway bar links ar F'ing KILLING me!

[boy412]

Just wrapping up my control arm (uppers and lowers) and steering rack install () and I'm stuck at re-connecting the sway bar links. Are there any tricks for getting these F'ing things back on? Everything else has gone moderately smoothly...so I'm puzzled why I'm having so much trouble. Nobody mentions problematic sway links in any of the suspension DIY's. The trouble I'm having is getting the bottom section to line up with the sway bar so I can thread the bolt in. I thought I had it on one side but what I was really doing is cross threading the threads in the sway bar.

I've tried everything I can think of. I loosened up the sway bar so I had more wiggle room but that didn't really help. I tried threading on the bottom first but then just had the same problem with the top threading onto the front lower control arm. If I can't get it sorted out I'll have to do the drive of shame to my shop and have them do it. For obvious reasons I don't want to do that. I've gotten this far only to be stumped by those two little F'ing pieces of metal!

If any of you suspension guru's are reading this I'd really welcome your input! Here's a photo of the old next to the new...because everybody likes pictures.

[old guy]

Loosen the sway bar bushing housings so you can align the links. Attach the links and then tighten up the bushing housings. I also had to place a large washer between the sway bar link and the end of the sway bar to keep the links straight.

[IMG][/IMG]

Have fun!

[OreOOO]

I attach the top first, leave it loose. Then get your bolt in the sway bar by jacking up on either the sway bar or control arms to line everything up.

[Mike@PureMS]

Lower the car on the ground, or jack up both sides of the suspension. Suspension has to be compressed to get them to line up properly.

[old guy]

Lower the car on the ground, or jack up both sides of the suspension. Suspension has to be compressed to get them to line up properly.

Good point. I forgot to mention that I had my car on ramps when I reattached the sway bar.

[boy412]

That could be it. I was trying to re-install mine while it was up in the air. I need to get the threads on one side of the sway tapped out so it will be a few days before I can give it another go. Thanks Fletcher, Mike, and OreOOO for the suggestions. Its super aggravating to come this far (seized pinch bolts, etc) only to be stopped by the sway bar end links.

The FCP control arm kit worked out pretty well! Some of the bolts were a little longer than their OEM counterparts but for the most part I'm pleased with my purchase.

[EErie B6]

ramps FTW!

then you can use a floor jack and a piece of 2x4 to help persuade things if you need to.

[Bische]

Make sure you get those real snug, otherwise you will get a real annoying clunk.

[boy412]

Now that I have a mostly quiet front end (like having a new car!) I definitely don't want to introduce any clunking. I'm giving serious thought to ordering a set of H-Sport sway bars instead of re-tapping the OE "Sport" one. That's been on the wish list for a while now.

Thanks John and Bische for the advice...

[EErie B6]

I think JHM still has their special going. Its a very worthwhile investment. If you pull the trigger, go with the B6 S4 (35/24mm) setup.

[boy412]

Yes...I was just on their site yesterday! Reading the product description leads me to believe that the S4/RS4 setup might be too "aggressive"? Remember I'm not building a car for AutoX!

Does anybody know off-hand what size the bolt is that threads into the sway bar? M10 x 1.5? Need to pick up a Heli-Coil kit to repair the threads I F'd up.

[EErie B6]

I have never owned the A4 (22mm) bar. Going from stock straight to the S4 (24mm) bars there were zero negatives. Ride quality does not change (for better or worse) and the car corners much better. Daily driving you don't know they are there, but when pushed to the limit it is much more stable & fun. With S4 bars on "soft" setting, the car still plows ever so slightly... and you still have the option to switch to "hard" for a track day if you ever attend one. I (even if I did not autocross) would not waste my time on the A4 (22mm) bar. I think that it would end up on the stiff setting with the user eventually wanting more.

...its one of the few mods I have done that had no negative effect for me to cope with. honest.


from what I understand, the RS4 (29mm) bar is a different animal... and that I would not recommend for a DD.

[boy412]

We'll see come payday if new sways are in the cards...I had planned on buying coilovers first.

[OreOOO]

Sorry to reply so late. I had my sway bar strip out on me too one time. Just go to autozone or home depot and buy a cheap tap and die kit. Mine was like $20. Use the measuring device in the kit and measure the threads on the bolt that will go into the sway bar. Just to make sure, run a die of the corresponding measurement on the bolt to make sure its the right size. Then I just used a cheap drill and the correct size tap with a little oil, works perfect.

[boy412]

I ordered a Helicoil kit off Amazon and will be tackling that later today.

I can't get over how much quieter the ride is with these new control arms attached. I didn't notice the noise until it was gone!

[Charles.waite]

I ordered a Helicoil kit off Amazon and will be tackling that later today.

I can't get over how much quieter the ride is with these new control arms attached. I didn't notice the noise until it was gone!

I hate threads like this, it just makes me add more stuff to my To-Do list.

btw AZ needs an unhappy wrenching icon...

[boy412]

The day wrenching turns into "unhappy wrenching" is the day I sell my car. I think I know what you mean though.

[Charles.waite]

The day wrenching turns into "unhappy wrenching" is the day I sell my car. I think I know what you mean though.

I'm just in a bad mood today. All banks suck, but I really hate Chase...

[boy412]

Yes. Yes they do.

[Elliott]

How many miles did you have on your OE set? I'll probably replace mine around 130k or so.

[boy412]

167k or so. Should have done this a LONG time ago! Sort of a pain in the dick to do...but if you can take your time its entirely worthwhile to do on your own.