Astro, Safari 1997-2005

Stabilizer Bar (Sway Bar) & Links

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Removal & Installation



  1. Raise and properly support the vehicle.
  2.  
  3. Remove the wheels to provide access (and light).
  4.  
  5. Disconnect the stabilizer bar link nuts, then slowly pull the bolts down, from underneath the lower control arms. As the bolts are removed, the retainers, insulators and link spacer will be freed from the bolt. BE SURE to note the locations for each of these components and keep them in order. It is probably best to install them in order over the bolt and put the nut on the end to keep any part from being lost.
  6.  
  7. Remove the stabilizer bar-to-frame clamps.
  8.  
  9. Remove the stabilizer bar from the vehicle. If necessary, remove the insulators from the shaft.

    Click image to see an enlarged view

    Fig. Exploded view of the stabilizer shaft mounting



    Click image to see an enlarged view

    Fig. Loosen the stabilizer bar link nut, while using a wrench to hold the bolt from turning . . .



    Click image to see an enlarged view

    Fig. . . . then remove the bolt, gathering each of the link components and keeping them in order



    Click image to see an enlarged view

    Fig. Make sure the offset on the bar is aligned properly during installation

  10.  

To install:

  1. If removed, install the insulators on the shaft. The slit on the insulator should be positioned toward the front of the vehicle.
  2.  
  3. Install the stabilizer shaft and brackets to the van, making sure the shaft is mounted with the identification on the right side of the vehicle. Install the shaft offset in the downward position and make sure the insulators are positioned squarely in the clamps.
  4.  
  5. Loosely install the stabilizer bar-to-frame clamps in order to hold the bar.
  6.  
  7. Install the stabilizer links through the control arms, positioning the necessary components (insulators, washers, retainers and the link spacer) as it is inserted. Connect the links to the ends of the bar, installing the washer and nut.
  8.  
  9. Tighten the stabilizer bar link-to-lower control arm bolts to 13 ft. lbs. (18 Nm) and the stabilizer retainer-to-frame bolts to 27 ft. lbs. (36 Nm).
  10.  



Click image to see an enlarged view

Fig. Exploded view of the stabilizer bar mounting


NOTE
Keep the right or left suspension components separated and do not interchange.

  1. Raise and properly support the vehicle.
  2.  
  3. If necessary, remove the wheels to provide access (and light).
  4.  
  5. Disconnect the stabilizer bar link spacer nuts, then slowly pull the bolts up, from above the control arms and shaft. As the bolts are removed, the nut, insulators and link spacer will be freed from the bolt. BE SURE to note the locations for each of these components and keep them in order. It is probably best to install them in order over the bolt and put the nut on the end to keep any part from being lost.
  6.  
  7. Remove the stabilizer bar-to-frame clamps. On some models the clamps are retained by bolts only, while other models may use both nuts (studs) and bolts.
  8.  
  9. Remove the stabilizer bar from the vehicle. If necessary, remove the insulators from the shaft.
  10.  

To install:

  1. If removed, install the insulators on the bar. The slit on the insulator should be positioned toward the front of the vehicle.
  2.  
  3. Install the stabilizer bar and brackets to the van. Loosely install the clamps to the frame in order to hold the bar in position. In order to align the holes in the control arm and stabilizer bar, it may be necessary to unload the torsion bars. For details, please refer to the Torsion Bar removal and installation procedure found earlier in this section.
  4.  
  5. Tighten the clamp bolts and nuts (as applicable) to 41 ft. lbs. (55 Nm).
  6.  
  7. Install the spacers, link bolts and nuts. Tighten the nuts to 13 ft. lbs. (150 inch lbs. / 17 Nm).
  8.  
  9. Load the torsion bars, following the Torsion Bar installation procedure earlier in this section.
  10.  
  11. If removed, install the front wheels.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Check and adjust the -Z'' height as outlined in the alignment information later in this section.
  16.  

 
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