I have a 96 Windstar and the sway bar rusted and broke. I removed it
and hardly noticed any difference but in the state I live it failed the
safety inspection. I'd like to get one more year out of this van,
anyone ever install a sway bar? I know it might be tricky to maneuver
through the underbody but I'm assuming it's possible. Can you buy one
aftermarket or is it a dealer item?

On one of my last cars the sway bar was, at least according to the
mechanics, "destroyed" to the point of no return. They mentioned I
could go purchase one on my own and if I had any automotive friends
they could install it, however they said the best bet would be to use
a company then it would be under warranty just in case something
happens to it.

I did a quick Google search and found a couple places selling a Sway
Bar kit that might work for you:

http://www.innerauto.com/browse/year...y+Bar+Link+Kit
<< $27 to $42 depending on the type of Windstar you have.

http://www.1motormart.com/parts/1/19...y+Bar+Link+Kit

Actually both of those look similar ... so I'm not sure if they are
pulling their products from a main provider or not ... but just
looking at the Sway Bar it seems pretty simple to install.

Scott



On Apr 25, 7:33 pm, rpms0... (AT) yahoo (DOT) com wrote:

rpms0605 (AT) yahoo (DOT) com wrote:
Stabilizer Bar:

Removal:

1. Raise vehicle on a hoist.

2. Support vehicle with hoist or safety stands behind front sub-frame.

3. CAUTION: Use extreme care not to damage boot seal. Do not use power
tools to remove nut or bearing and seal damage will result. Loosen the
nut first, then remove nut from stud using hex hold feature.

Remove and discard nuts retaining stabilizer bar link assembly to front
stabilizer bar and front shock absorber with an 8 mm closed-end wrench
and an 18 mm open-end wrench.


4. Remove nuts retaining power rack and pinion steering gear to front
sub-frame, and move power rack and pinion steering gear off the front
sub-frame.

5. With another set of support safety stands under front sub-frame,
remove two rear subframe retaining bolts. Lower rear of the front
sub-frame to obtain access to stabilizer bar brackets.

6. Remove front stabilizer bar U-bracket bolts and replace stabilizer
bar brackets and/or front stabilizer bar as required. Discard stabilizer
bar insulator and bolts.

Installation:

1. Clean front stabilizer bar to remove dirt and contamination in area
of stabilizer bar insulator installation position.

2. Lubricate inside diameter of new stabilizer bar insulator with Rubber
Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford
specification ESF-M99B112-A. Do not use any mineral or petroleum based
lubricants as they will deteriorate the rubber stabilizer bar insulators.

3. Install new stabilizer bar insulators onto front stabilizer bar and
position them in approximate location with slits to the rear of vehicle.

4. Install stabilizer bar bracket on front sub-frame and install new
bolts. Tighten to 30-40 N-m (22-29 lb-ft).

5. Raise front sub-frame and install new front sub-frame-to-body
retaining bolts. Position power rack and pinion steering gear onto front
sub-frame and install retaining nuts. Tighten to 115-135 N-m (85-99 lb-ft).

6. CAUTION: Use extreme care not to damage boot seal. Do not use power
tools to tighten nut or bearing and seal damage will result. Install nut
using hex hold feature to prevent the stud from rotating.

Install stabilizer bar link to front shock absorber and to front
stabilizer bar, making sure the stabilizer bar link is properly
positioned. The letters "Top LH" and "Top RH" are moulded into the
stabilizer bar link for correct assembly to the front shock absorber strut.

7. Install new nuts and secure stabilizer bar link assembly to front
stabilizer bar and front shock absorber. Tighten to 77-103 N-m (57-75
lb-ft) at front shock absorber strut and 47-63 N-m (35-46 lb-ft) at
front stabilizer bar.

8. Remove safety stands.

9. Lower vehicle.

Piece of cake.

Rob