[greffett]

Went to change sway bar endlinks and bushings the other day and ordered the energy suspension kit. according to the catalog, only one kit is offered for 99-04 superduties, and it showed all having 1 1/4 inch swaybars. Well, my 03 only had slightly bigger than a 1" bar. I called ES and they told me that I should have a 1.25 bar. A visit to ford indicated that my bar was right, and according to them, only the cab/chassis trucks have the 1.25 bar. ended up only slightly more expensive to just get the 1.25 bar and it fit my truck fine. So, the question is, is ES smoking dope, or did I get some weird combo truck that had an odd smaller front swaybar? has anyone else experienced this?

 

[Going_Going_Gone]

I installed an ES kit. When I did, it seemed that the sway bar bushings were a snug fit but as it turned out, they were too snug. They clamped the bar so tightly they restricted normal bar movement...then the bar would break loose with a clunk. After retorquing the link bolts and greasing and re-greasing the bushings multiple times with no effect; I re-installed my stock D-bushing and the clunk went away. I suppose I could have reamed the red bushings out, but I just tossed them in the toolbox. The urethane bushings couldn't make it corner like a Corvette anyways.

 

[my03psd]

This Energy Suspension 4.5186 Complete Front Sway Bar and End Link Bushings Set - 32MM is the kit I used everything was the right size.Hope this helps.

 

[Motoman]

Just be sure to mic the sway bar to know the exact size you have and then order appropriately.....

Here's the page from Summit for the ES bushings

Sway Bar Mounting Bushings - summitracing.com

and they show these different sizes for my year truck

Sway Bar Diameter (in)

• 1 in.,
• 7/8 in.,
• 1 1/8 in.,
• 3/4 in.,
• 5/8 in.,
• 1 1/4 in.

And the same thing for the rear ........ it's important that you get the right size or you will experience what Going GOing Gone was saying.....

 

[dieselhappy]

How can you tell if your sway bar bushings are worn out. If they are what should I see? How will the truck react?

 

[Motoman]

If you are getting a clunking under the floor board or a popping over shallow bumps and diagonal bumps ...... if you remove one side link and go for a drive and it goes away you found the source!