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Addco 1 1/8", 1 1/4" & 1 3/8" Rear Anti Sway Bar Installation Instructions
For the 89-97 Thunderbird, Cougar and the 93-98 Mark VIII

By: Mark McCormack, Vice President TCCoA

This installation of the 1 1/8" and 1 1/4" rear anti sway bar kit should only take about one hour or less to complete. The 1 3/8" kit will take slightly longer.

Tools and Parts Required:
Note: All of these tools may not be needed for your car.

* 1/2" deep socket
* 9/16" socket
* 3/8" socket wrench with 4" or 6" extension
* 9/16" open end wrench
* 1/2" open end wrench
* 3/8" universal joint
* Bench vise (it would be helpful)
* 2 nylon wire ties (zip ties)
* Hammer, preferably a small hand held sledge hammer (see pic)
* A set of car ramps or maybe 4 lengths of 2x6 boards

The first thing you should do is find a level place to work and then back the car up on the car ramps or up on 2 doubled up 2x6 boards under each rear wheel. All you are trying to do is get the rear end up enough to be able to work under the car. Set the parking brake.

Step One: Remove the 1/2" nuts on the end links.

Step Two: Cut the Ford mounting straps (zip ties) that hold the E-brake cables to the sway bar. Remove the bolts on the brackets that attach the bar to the frame. You may need the universal, socket and extension for this because of the bolt's close proximity to the exhaust system.

Step Three: Remove the old sway bar. It may be necassary to unhook one muffler from its rear bracket to make this job easy.

Step Four:
NOTE: This step is only necessary with the 1 3/8" kit.
You need one of the new 1 3/8" sway bar bushing and the two old sway bar frame brackets for this step. It will be necessary for you to spread open the stock brackets far enough so that they accept the 1 3/8" bushings. An easy way to do this is use the corner of a 4x4 or larger piece of wood. Place one of the two brackets as shown in the pic below and hit the rounded part of the bracket with the hammer to slightly spread open the bracket. Use the new bushing to test to see if the bracket has been opened up enough to accept the bushing. Keep testing the fit as you slowly open up the bracket until the bushing fits properly. Repeat this step for the remaining bracket.

Step Five:
NOTE: This step is only necessary with the 1 3/8" kit.
After the brackets have been modified to accept the new larger bushing, it is necessary to realign the bolt mounting ear of each bracket back to 90 degrees (see pic below). This can be accomplished with the aid of a bench vise. This ends the modifications to the brackets.

Step Six: Lube and install the new center bushings on the bar with the cut ends toward the rear of the car and hook the modified brackets in place. Place the bracket bolt in the bracket and then install 2 of the 1/2" washers on the bolt (bolt, then bracket, then washers - see pic below). Repeat this step for the other bracket. Lift the sway bar up into place and bolt the brackets into place, making sure the bar is centered on the brackets.

Step Seven: Install the end links as follows: (Threads of the bolts for the links must be on the bottom) Bolt, washer, bushing, bar, bushing, washer, sleeve, washer, bushing, lower control arm, bushing, washer then nut. Tighten the nuts until the bushings are snug enough that you can barely spin the sleeve with your fingers. This means just as the bushings start to be compressed. Do not over tighten.

Step Eight: Secure the E-brake cables with the plastic wire ties. Inspect all of your work. This completes the installation of the sway bar kit.

Please take your time to get acquainted with how your car now handles; as you will find that cornering, etc. will be very different. Good luck and have fun!!




Installation Photos
 
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