[marvins_dad]

How-To by tsuter

PLACEHOLDER - http://forums.newbeetle.org/showthread.php?s=&threadid=54673

Front H&R 26mm Sway Bar Install - How to

It's no wonder that the front sway bar update on New Beetles is not seen very often. The install can be a PITA as you must lower the subframe and disconnect the steering rack. But when you look at the flimsy 22mm front stock bar and the even flimsier stock drop links, you can see that an uprade to an H&R 26mm with VF Engineering solid drop links is a good idea.

With this setup I would run an H&R 28mm rear sway bar... in fact I do!!

Here are the steps...

First, securely jack up the front of the car and place on wheel stands. I used the removed wheels as a secondary safety measure at the sides:

 

[marvins_dad]

You will first remove the three lower plastic sound and dirt shields using your handy T20 Torx. No pics.

Then remove the rear engine to sub frame mount. Its uses four hex bolts 13mm and 16mm. The picture is of the VF Engineering mount coming off.

 

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Next you will unscrew the four bolts that attach the steering rack to the upper surface of the sub frame.

Four long 13mm bolts. These can be reused.

 

[marvins_dad]

Here is a drawing of the steering rack. The four bolts go in the four corners of the casting--part number

#14. Notice the locator positioning pin on the drivers side front of part number 14 in the drawing. This is very important.

SteeringRack

 

[marvins_dad]

You will then need to use your hydraulic jack to support the lower sub frame assembly as you will need to lower it 4-6 inches to gain access. It is bolted on by four monster stretch bolts that must be replaced

when you reinstall the sub frame.The front two go up thru the pillow block mounts on the frame.

These are 21mm hex bolts and they are 70ft-lbs you will need a serious breaker bar to get them loose.

 

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Remove all four bolts

 

[marvins_dad]

Use the hydraulic jack now and slowly lower the sub frame 1-2 inches. Watch and you will see that the steering rack on top of it does probably not separate.

That is because on the drivers side above the pillow block is a the positioning pin in the steering rack and it is stuck/wedged below the sway bar. See my finger. Use a large screw driver to pry the steering rack loose. You do not want the steering rack to be pulled down as you lower the sub frame.

 

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Now you can go back and lower the sub frame some more to about 5 inches below the pillow block mounts.

 

[marvins_dad]

Go ahead and have one beer now then remove the stock POS sway bar end links. You cannot believe how cheap these are.

You'll need a 16mm open end wrench.

 

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Here it is off. Save the hardware.

 

[marvins_dad]

Now remove the bolts securing the sway bar clamps to the pillow blocks. 13mm hex and you can only get to these thru the wheel weels with the sub frame lowered.

Here is the passenger side:

 

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And the drivers side....

 

[marvins_dad]

The stock sway bar can now be removed by rolling the ends of the sway bar backwards over the drive axels

and then working it forward until it comes out. No pictures. Its loose. You'll figure it out. Set the clamps to the side as you will reuse them but not the bushings.

Have your second beer now after the stock sway bar is off.

Now you get to remove the upper bolts from the stock drop links to prep the new drop links.

 

[marvins_dad]

The trick to this is to use a socket and a bench vice to press them out of the rubber bushing. That is the only easy way.

 

[marvins_dad]

Now the removed bolt must be pressed into the new VF Engineering drop links. You are NOT reinstalling those cheap stock drop links right????

 

[marvins_dad]

Use the same technique.. A large socket and a bench vise and press them into the new drop links.

FR033, 034, 036.

 

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And press...

 

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And done...

 

[marvins_dad]

Now go ahead and put the new sway bar into position in reverse motions as you took the other one out:

Hang it over the axels..

 

[marvins_dad]

Make sure you put the existing clamps in place over the sway bar bushings in the right orientation before you hang the sway bar back in there.

When you get it in take a third beer break... you'll need it.