You say you're 500 under GAWR-Front. 5000-500 is 4500-lb. If you have 215/75R16E tires, 65-PSI gives you 2335-lb single for the front, or 4670-lb. 75 is over-inflation and I can tell you that you WILL feel it in tracking and unwanted response to cross winds. You can run rear tires above charted pressure and probably many front tires. Just NOT Ford E-Series!!!
Load - Pressure ChartWhen I visited Henderson's, I noticed they use the Safe-T-Plus and that surprised me. They sell lots of Roadmaster stuff so I expected they'd promote Roadmaster Reflex. I didn't ask why, but while there, I noticed they use a variety of brands, picking what they feel is best, not loyalty to one product line.
When I changed our front sway bar to Hellwig, the new bar came with bushings, larger brackets and spacer plates to go between the frame (radiator support area) and the new brackets. The old brackets did NOT use spacers but the instructions called for re-using the original bolts, and they reached.
THAT I remember. I also believe the Hellwig rear bar re-used original bolts. I don't think it added spacers, but I can look if you need me to.
An OP here, Deprived, did the front axle upgrade carringB and I did, and Holiday27 had done at QuadVan. Deprived wanted to up-size the bolts to match the size used on 2008+ chassis. I forget what went wrong, but he ended up calling a welder to the scene. I don't think I'd recommend messing with the bolt sizes. Hellwig doesn't and the diameters of the upgraded front bars are the same in the early and late model versions. Neither carringB or I have experienced any looseness.
Both Hellwig bars are "No Drill" installations. They either re-use or re-purpose existing holes. I installed both of ours without an assistant. I had to adjust the height I'd raised the front to, in order to get the old bar pulled out of the bushing holes in the axle. With late model, you don't have that design, so I can only think the late model bar would drop right down and the new bar would go right up. I don't think I raised the rear, if so it wasn't much. Rear bar is heavier but I laid it on the box it came in and that was enough to let me position it. All you have to do is get it approximately positioned then catch one of the rear axle brackets, even without the bushing. Once you do that, it's easy to manage for final assembly.
What didn't you like about the Reflex RSSC?
What are the Caster, Camber, and Toe settings after alignment?
I hope I answered all the items in your post. If not, let me know.
