Huge Hellwig Disappointment!

[Rbertalotto]

Took this afternoon to install my Big Wig, Hellwig rear stabilizer bar on my 2006 Dodge, 2500 Diesel.

Unfortunately, nothing fits!

The box says it is for a 03008 5.9L truck


The small parts box within the main box says the same thing:


But the saddles to go over the axle do not fit. One leg is supposed to go over the center section casting and the other on the axle. But it will only go over the cast center section. The other leg hangs in free air




I could modify this saddle bracket by cutting one side to fit the center section so the other leg would contact the axle tube, but it gets worse.

The "U-Plate" hole spacing does not match the saddle bracket or the U-Bolt:


It will be interesting to see how quickly this gets resolved. Sure hope I don't have to send the whole thing back!

[AnEv942]

Wouldn't the dogleg offset in the links make up the 6" difference in the width of frame verse sway bar? Plus frame bracket just a tad off to side.
Couldn't say on the bushing clamp unless they just got pinched-tried to insert bushing?
The axle saddle though if both 'ears are cut at same radius, obviously it isn't going to fit both the tubes and center section. I was thinking (contrary to instructions) maybe intent was to butt up against center section but does not look there is any room width wise.
Hmm-unfortunate as its Sat, cant talk to anyone for 2 days.

[kerry4951]

Four years ago when I bought mine I was missing parts. A few others around that same time experienced the same problem. Now they are packaging the wrong parts. I think for the next one I will do some serious looking at the Roadmaster.

[Rbertalotto]

I just did some more measuring.



My frame rails are 39” apart, center to center



The sway bar I received is only 33” center of eye to center of eye



http://public.fotki.com/Rbertalotto/vehicles/dodge-cumming-diesel/1404597452970.html

http://public.fotki.com/Rbertalotto/vehicles/dodge-cumming-diesel/1404597453667.html



So even if I modified the saddle brackets, the bar is too narrow.



Also as an FYI:



My frame rails are a box 3” wide by 6” deep

[Mello_Mike]

Hi Roy,
You shouldn't have to modify anything. I just did this install back in Jan and it's pretty easy. I did double check 7265 and it is the one made for your truck. Are you straddling the axle bracket over the casting lip and not the one side on top of it? If you are and it still doesn't fit right you may have some mislabeled parts. Hellwig will work with you. They have great customer service.

My Hellwig Install

[msiminoff]

Rbertalotto wrote:
Sure hope I don't have to send the whole thing back!

Sending this one back may seem like a drag… but once you get your RoadMaster anti-sway bar installed it will have been worth the effort. 😉
-Mark