tmcolegr
It's All About the Build
First off let me say this redesigned product (now fits 2005 - 2012 vehicles) is first class along with BMR's Customer Service. I can't say enough good things about Kelly as he patiently answered all my questions - even the stupid ones.
Rather than posting a Taco Bill style step by step installation, I'll just hit the highlights. I think most everyone already understands how the Anti Roll Bar physically mounts on the vehicle, so I'll keep this post focused on "attention to detail". It goes without saying this installation should be done with the vehicle at ride height, suspension loaded and rear axle centered in the chassis. Here's a link to BMR's installation instructions.
The BMR chassis mount shares the same mounting points as the front muffler hangers (which require a slight modification) and OEM rear sway bar chassis mounts. BMR does not supply new hardware at these locations (at least not in my kit). I purchased longer bolts and heavy duty flat washers for the muffler hanger mounts as the holes in the mounts are over sized and the OEM bolt/washer did not fit to my liking.
I also purchased 1/2"-20 x 2.75" grade 8 bolts for the OEM rear sway bar chassis mount to BMR chassis mount. BMR did not supply these bolts. Rather they reuse the OEM rear sway bar hardware. The 1/2"-20 bolts fit tighter in the vehicle chassis and BMR chassis mount. This should help reduce some chassis noise as I plan on running this vehicle on the street. Notice each side of the OEM chassis mount bolts have hardened washers and have 2-3 threads protruding through the locknut.
The sway bar attaches to the chassis mount with 2 very nice billet aluminum mounts. Notice the socket head cap screws, hardened flat washers and lock nuts. Another item worth mentioning, is the sway bar can be mounted as you see in the picture or inverted. It makes absolutely no difference as to the performance of the product but was intended to be installed as shown. Bushings were pre-greased at assembly. BMR's Superlube provides a friction free pivot point.
The sway bar end links fit inside the sway bar. There are 2 thin washers that fit on each side of the lower rod end making this a very snug connection. You'll also notice I used longer bolts so I could use a hardened flat washer on both the bolt and nut side of the fastener.
The installation of the weld on axle tabs, in my opinion, is one of the critical items that makes the difference between a mediocre installation and a very professional installation.
The end links should be as vertical as possible to prevent binding. Here is where the decision needs to me made as to which hole you will use for the lower end link to sway bar connection. Due to the 2 holes in the sway bar being at different distances from the pivot point of the sway bar, the angle of the end links will change depending on which hole you use. I will be using the end hole (hole farthest away from the pivot point of the sway bar) as I believe this will be correct for my specific application. I'm sure Kelly will chime in (Hint) when he reads this thread to elaborate on how to determine which is the correct hole to use based on BMR's experience.
The radius of the weld on tabs has been carefully blended to fit the exact radius of the axle housing.
All paint has been removed from the axle housing so the welds will have good penetration. I personally will not be performing the welding as I'm not a welder. The welding will be performed using a mig welder with .035" solid core wire.
As previously mentioned, the end links should be as vertical as possible - both fore & aft and left to right, prior to welding the axle tabs. The bolts I have installed in the upper mount of the end links are only temporary. Once the tabs are welded in place, these bolts will be replaced with hardware as you see at the lower end link location. Final adjustment of the sway bar (sway bar billet mounts have slotted holes) will be made once installation is completed. End link angles will be measured with a digital angle gauge accurate within .1*.
Here's a rear view of the installation (minus welding the axle tabs to the axle). If you'll look closely, you'll see a bungee cord temporarily holding the sway bar in place while I position and tack weld the sway bar end links to the axle housing.
By now you'll have noticed I frequently mentioned replacement hardware that was not supplied with the BMR Xtreme Anti Roll Bar. I want to say there is absolutely nothing wrong with the grade 8 hardware supplied by BMR - I just prefer to use Caterpillar grade 8 phosphate & oil coated hardware. I also used a hardened flat washer between the head of any bolt or nut rather than tightening either directly against a part. I also prefer Caterpillar hardware due to the increased head height when compared to other manufacturer's hardware.
PS: after reading all the other posts on Xtreme Anti Roll Bar installation and adjustment, others have posted the sway bar should be horizontal. This is not possible with the redesigned Anti Roll Bar as the end link's length is too long to position the sway bar horizontal. I will be adjusting as per BMR's "Swaybar Setup" in their revised installation instructions.
Please feel free to ask questions.
Rather than posting a Taco Bill style step by step installation, I'll just hit the highlights. I think most everyone already understands how the Anti Roll Bar physically mounts on the vehicle, so I'll keep this post focused on "attention to detail". It goes without saying this installation should be done with the vehicle at ride height, suspension loaded and rear axle centered in the chassis. Here's a link to BMR's installation instructions.
The BMR chassis mount shares the same mounting points as the front muffler hangers (which require a slight modification) and OEM rear sway bar chassis mounts. BMR does not supply new hardware at these locations (at least not in my kit). I purchased longer bolts and heavy duty flat washers for the muffler hanger mounts as the holes in the mounts are over sized and the OEM bolt/washer did not fit to my liking.
I also purchased 1/2"-20 x 2.75" grade 8 bolts for the OEM rear sway bar chassis mount to BMR chassis mount. BMR did not supply these bolts. Rather they reuse the OEM rear sway bar hardware. The 1/2"-20 bolts fit tighter in the vehicle chassis and BMR chassis mount. This should help reduce some chassis noise as I plan on running this vehicle on the street. Notice each side of the OEM chassis mount bolts have hardened washers and have 2-3 threads protruding through the locknut.
The sway bar attaches to the chassis mount with 2 very nice billet aluminum mounts. Notice the socket head cap screws, hardened flat washers and lock nuts. Another item worth mentioning, is the sway bar can be mounted as you see in the picture or inverted. It makes absolutely no difference as to the performance of the product but was intended to be installed as shown. Bushings were pre-greased at assembly. BMR's Superlube provides a friction free pivot point.
The sway bar end links fit inside the sway bar. There are 2 thin washers that fit on each side of the lower rod end making this a very snug connection. You'll also notice I used longer bolts so I could use a hardened flat washer on both the bolt and nut side of the fastener.
The installation of the weld on axle tabs, in my opinion, is one of the critical items that makes the difference between a mediocre installation and a very professional installation.
The end links should be as vertical as possible to prevent binding. Here is where the decision needs to me made as to which hole you will use for the lower end link to sway bar connection. Due to the 2 holes in the sway bar being at different distances from the pivot point of the sway bar, the angle of the end links will change depending on which hole you use. I will be using the end hole (hole farthest away from the pivot point of the sway bar) as I believe this will be correct for my specific application. I'm sure Kelly will chime in (Hint) when he reads this thread to elaborate on how to determine which is the correct hole to use based on BMR's experience.
The radius of the weld on tabs has been carefully blended to fit the exact radius of the axle housing.
All paint has been removed from the axle housing so the welds will have good penetration. I personally will not be performing the welding as I'm not a welder. The welding will be performed using a mig welder with .035" solid core wire.
As previously mentioned, the end links should be as vertical as possible - both fore & aft and left to right, prior to welding the axle tabs. The bolts I have installed in the upper mount of the end links are only temporary. Once the tabs are welded in place, these bolts will be replaced with hardware as you see at the lower end link location. Final adjustment of the sway bar (sway bar billet mounts have slotted holes) will be made once installation is completed. End link angles will be measured with a digital angle gauge accurate within .1*.
Here's a rear view of the installation (minus welding the axle tabs to the axle). If you'll look closely, you'll see a bungee cord temporarily holding the sway bar in place while I position and tack weld the sway bar end links to the axle housing.
By now you'll have noticed I frequently mentioned replacement hardware that was not supplied with the BMR Xtreme Anti Roll Bar. I want to say there is absolutely nothing wrong with the grade 8 hardware supplied by BMR - I just prefer to use Caterpillar grade 8 phosphate & oil coated hardware. I also used a hardened flat washer between the head of any bolt or nut rather than tightening either directly against a part. I also prefer Caterpillar hardware due to the increased head height when compared to other manufacturer's hardware.
PS: after reading all the other posts on Xtreme Anti Roll Bar installation and adjustment, others have posted the sway bar should be horizontal. This is not possible with the redesigned Anti Roll Bar as the end link's length is too long to position the sway bar horizontal. I will be adjusting as per BMR's "Swaybar Setup" in their revised installation instructions.
Please feel free to ask questions.
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