Has anyone ever tried to replace the front swaybar bushings for my year or 90-95

My sway bar is 27mm and the bushings that I bought do not fit my ome brackets.

I can't use new brackets because the holes that mount to the frame are offset.

 

Can you redrill the new brackets?

 

I tried and it made the hole so big that a bolt with a washer would pull through.

 

Here's progress:



I need to cut the other one and weld them up. There may be a clearance issue with the bracket and the stock bolts. You might need to go to allen head bolts for clearance since the holes are really close to the area where the bracket goes up over the bushing.

Disclaimer: I have no affiliation with Minute Man Press other than their free paper.

 

Mike:
Looking great!!! It really illustrates the fact that on the 90-95 runners, the sway bar bushings are 27mm & the bracket holes are offset on the tabs. Most sites I go on say 24mm front sway bar bushings. I was beginning to wonder if my sway bar had been replaced. But you confirmed it was the right size.

You've got a good point with the allen head bolts.

Thanks again Mike.

 

How about a few more pics?



Tool and cutting wheel of choice:


Tough to snap a pic one handed while cutting...




Cleaning it up:


The TIG rig:


Need to clean her up a little prior to paint..

 

So is there no "bolt-on" application for these???

I thought that was the whole point.

are all of the 2nd Gen swaybars 27mm or 24mm??

Mike

p.s. I dont have a Tig welder.......want to fab me a set??

 

I figured out a better way to modify these to work. PM me what it's worth to you for the mods and we'll see if we can strike a deal... Cat-o-leen will be getting the new and improved ones when I get a chance to do them (modifying a set of existing ones). I have a small bender for brackets and such. When I get a chance to dabble, I'll try to make a set from scratch (not likely anytime soon)

I emailed Energy Suspension and told them the bracket doesn't work for this application. I also told them I butchered a set of brackets and would appreciate another set of brackets, but they haven't gotten back to me.

 

Here's Photo Mike's (2nd Generation ES Swaybar Bracket Mod):

The brackets:


With the 1/8" thick "chicklets" cut:


Shaped and fit into existing hole:


Ready for torchin':


I need to check the rears on mine to be sure this way will work, but there's snow on the ground and it's really cold outside. Tomorrow is another day! Hoping to have both sets all torched up/painted tomorrow evening for shipping Wednesday.

 

I saw my links were broken. Here's the pics from my current host:

 

Is the outside dimension of the Energy bushing the same as the OEM bushing? If so, couldn't you just use the stock bracket and drill a hole for a zerk? I'm trying to figure out what to do with mine.

 

The outside dims of the bushing is larger. It does not fit in the OEM bracket at all. That's the reason for the mod.

 

Interesting to see they have never fixed this problem. Unbelieveable really.
I put urethane bushings on my 85 back around 86 - same fitment issue. 20 years later same same. Good thing they don't make critical parts!

I just squeezed em in and used cap screws (allen head bolts) too, worked fine.