Hellwig 7648 Sway Bar question

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Duncan Kimbro

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Guys, I have a question about what the sway bar for a 1st Gen Trac should look like. I was able to buy the discontinued Hellwig 7648 Sway Bar for the 2003 Trac just before I traded it in last month, but never installed it. I got it directly from Hellwig, after their national sales manager had the folks at the warehouse check their old returns pile, on the condition that it was non-returnable since it was discontinued.

When I was taking the photos below so I could post it for selling, I noticed that the end link on one side (passenger side I think?) is slightly curved, while the other side is straight, so it isn’t perfectly symmetrical. I cant check fitment because the old truck is gone. I’ve looked at some other photos of the Hellwig and EE sway bars online, and it sort of looks like that end should be slightly curved, but it’s hard to tell.

Does anyone whose installed one of those (or the EE bar) tell me if it should have a slight curve? I want to give it to my brother for his 2004 Trac, but don’t want to to do that if it's defective or won’t fit or would be unsafe.

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That's interesting Duncan because I'm using the Addco 633 and both trailing arms are straight. Guess that means there are no larger aftermarket rear or front sway bars for 1995-01 Explorers or 2001-05 Sport Tracs now. Don't remember anyone on MySt or this site using the Hellwig, but think there's a few on EF using them. I can PM for you if you would like. BTW, I would be using the EE "X-Spec" rear sway bar, but they quoted me $175 non negotiable ground shipping to Hawaii. Never called EE again.

Hellwig's 7648 generic pic on Summit Racing's site appears one side is curved down. (Click +)
https://static.summitracing.com/global/images/prod/xlarge/HEL-7648_xl.jpg?rep=False
 
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Thanks, Steve, that would be great. I can post the there but I don't think I can post photos. I probably need to join as an Explorer Elite member.

I think that's the same photo on all the sites for the Hellwig bar, and it does look like there's a curve.

On the bar itself, the curve "looks" intentional and it doesn't look like it was damaged. It's pretty rugged and the metal doesn't look like it was accidentally deformed. The powder coating is intact and it doesn't look like it was ever installed. I imagine it would take a huge amount of force or forging to bend it.
 
If I might make a comment... you stated that you wished to give it to your brother for his ‘04 sport trac. Today I spent a long time on-line and speaking to personnel at several larger aftermarket suppliers of suspension parts. NO ONE had or made any heavy duty front or rear sway bars for the 2004 model. That being said, I learned that Explorer Express did make these sway bars for years up to 2001. I am/was bummed out. Sorry to be a bearer of bad news... I think.
On the other hand, I was just going to post a question to forum members about ROADMASTER Active Suspension kits ... (I think that is their correct name). Apparently they do make a “very good product” that eliminates sway/squat/roll even when there is no payload in bed of truck. Supposedly this is what is desirable for poor/wet/bumpy road conditions. Maybe this will be of help, I sure know that I want better handling for my ‘04 sport trac 4x4, especially in adverse weather conditions.
Has anyone heard of, or used, or had experience with this type of rear suspension system?
Today, when I spoke to “Will” at “Roadmaster” I was told that the custom (by year, make, model) systems are on sale thru tomorrow at a pretty good discount...
Hmmm... should I pull the trigger or not...? By the way, there is a 30 day satisfaction guarantee.
Hope this info helps, let me know.
 
Pics are EASY to post on EF WITHOUT being Elite. Join a photo hosting site such as Imgur, copy the BB code, and paste it on your post.

Really don't think you need to check though. 4140 chromoly steel is incredibly strong and unless the powder coating is scraped or scuffed I doubt it was bent or damaged. I know how strong chromoly steel is because I whacked my chin hard on a HOLLOW motocross bike handlebar and it didn't budge. If it hadn't been for my full face helmet I'm sure I would have broken my jaw and maybe more. That happened a long time ago. Still have pics of the broken helmet somewhere. Not pretty. LOL
 
If I might make a comment... you stated that you wished to give it to your brother for his ‘04 sport trac. Today I spent a long time on-line and speaking to personnel at several larger aftermarket suppliers of suspension parts. NO ONE had or made any heavy duty front or rear sway bars for the 2004 model. That being said, I learned that Explorer Express did make these sway bars for years up to 2001. I am/was bummed out. Sorry to be a bearer of bad news... I think.

I'm pretty sure what you were told is because the aftermarket sway bars and suspension were typically listed as being for the Explorer through the 2001 model year, but will fit the 1st gen Sport Tracs (2001 through 2005). Someone can correct me if I'm wrong, but I think they share almost all suspension parts.
 
Pics are EASY to post on EF WITHOUT being Elite. Join a photo hosting site such as Imgur, copy the BB code, and paste it on your post.

Really don't think you need to check though. 4140 chromoly steel is incredibly strong and unless the powder coating is scraped or scuffed I doubt it was bent or damaged. I know how strong chromoly steel is because I whacked my chin hard on a HOLLOW motocross bike handlebar and it didn't budge. If it hadn't been for my full face helmet I'm sure I would have broken my jaw and maybe more. That happened a long time ago. Still have pics of the broken helmet somewhere. Not pretty. LOL

Yep, that's my thinking, too, and I know the chromium-molybdenum steel alloys are used specifically for strength and hardness. That said, the engineer in me likes to be sure. I spend a lot of my workday thinking about dangerous things and consequences and liability, so I've been trained to be cautious and conservative. ;)

i was thinking about selling it before I decided to give it to my brother, so I thought I'd better be able to answer the question of why it isn't symmetrical. With it going to my brother, we can easily just check fitment on his truck.
 
If I might make a comment... you stated that you wished to give it to your brother for his ‘04 sport trac. Today I spent a long time on-line and speaking to personnel at several larger aftermarket suppliers of suspension parts. NO ONE had or made any heavy duty front or rear sway bars for the 2004 model. That being said, I learned that Explorer Express did make these sway bars for years up to 2001. I am/was bummed out. Sorry to be a bearer of bad news... I think.
Unless you're loading the bed with lot's of weight or towing with heavy tongue loads it sounds like upgrading your REAR sway bar would be a much better and cheaper option. IMO, adding a larger REAR sway bar was the best handling improvement I've ever done after tires, shocks, and lowering. An upgraded rear sway bar virtually eliminated body roll when turning and made the ST much more stable when windy. Unfortunately the EE "X-Spec". Addco 633, and Hellwig 7648 REAR sway bars are all discontinued so you will need to find a used one. Aftermarket REAR sway bars for 1995-01 Explorers bolt up to 2001-05 (Gen 1) Sport Tracs perfectly. Be aware that FRONT sway bars for earlier Explorers had different frame mounting points so you need to compare with yours.

https://web.archive.org/web/20101219183449fw_/http://mysporttrac.com/shared/projects.asp?VIEW=132&WRENCHES=2&PageHeader=Member Projects

Addco 737 FRONT sway bar also discontinued and no longer available.
https://web.archive.org/web/2012032...c/projects/InstallingtheAddcoFrontSwayBar.pdf
 
^ Thanks Duncan, that's really good to know. Wonder how much new old stock (NOS) of the Addco 633 SD Truck Springs has?
 
SD Truck Spring still lists the Hellwig 7648 on their site. Insanely expensive shipping to Hawaii. Cheapest method $190.62 for Hellwig, and $82.68 for Addco. Both UPS 2nd Day Air. Must be drop shipped from both.
 
Check stock..... they still list them but no stock....
 
Just wanted to post a pic of the highly regarded "X-Spec" (ZD5622) rear sway bar found in my old files.

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