Sway bar again 34mm or 32mm

[mediccummin]

Just received my energy suspension kit 5. 5126R which is suppose to be 32mm for our truck but when I measured I got 34mm. When I attempted to put this bushing on it has about a 1/4" gap before it touches together. Those of you using these have you had the same problem, will it touch when I clamp it down. I talked with energy suspension and they said that the application number above is not for the Diesel and that they believe the diesel has a bigger than 32mm sway bar. He said if I clamp it down with this amount of distance that it will split the bushing. From what he told me was they don't make a kit for the Diesel. If anyone has any experience with this let me know thanks... .....

 

[John]

Oops! mediccummin, you've got the wrong kit. You have the 32 mm kit. When you install the split urethane bushing, the gap should be pretty small.



32 mm bar = 1. 260"



34 mm bar = 1. 339"



BTW, yes they do have a kit to fit Cummins TD powered Rams. I have it (in black... although, I didn't use the front mounts because of intereference between the increased height of the Energy Suspension mounts and the G1 DSS unit).



Also, I was told by someone at a local Central 4WD shop that Energy Suspension has their part numbers all screwed up. Apparently those that order from them quite frequently can accurately navigate through their shortcomings although, I was also told, "Energy Suspension is working on it. "

 

[Clinton]

I've been trying to figure out how to get the correct Energy Suspension sway bar kit all week. mediccummin, your first thread on the subject is what got me going. I'm not sure anybody knows for sure what fits the CTD Ram. 4Wheel Parts Wholesalers couldnt'tell me and refferred me to Energy who swears up and down they don't make a kit for the CTD Ram with 34 mm sway bar. The 5. 5126 Energy part # is definitely for a 32 mm bar. Energy says you may be able to piece the correct parts from their braket part numbers. May be able? The guy I spoke with knew less than I did.



Okay, enough on the rant. Would one of you folks that ended up with the correct kit please post the part number for retailer you dealt with? I'm more interested in the links than the frame bushings and brackets. My links are whats shot. Thanks for the help.

 

[John]

Clinton, I purchased the Energy Suspension 34 mm sway bar kit to fit my 34 mm OE Dodge sway bar (as also stated in my previous post)... medicummin knows this too (we PMed each other several times exchanging information). I also stated that Energy Suspension has shortcomings... another one of them must be employees that don't even know there product applications.



Irrespective, I still maintain that the Energy Suspension kit will not fit IF you also have a DSS. There is an intereference fit by at least 1/4" because the Energy Suspension urethane mount and steel cradle are "taller" (distance from the bottom of the mount to the bottom of the sway bar hole), meaning they sit "lower", away from the frame when installed. That doesn't pose a problem by itself but, you are pretty much held hostage with the DSS... they only took into account the OE sway bar mounts when designing their trick stabilizer which has a lower profile design. And yes, I know "Hemi" has a G1 DSS with an Energy Suspension sway bar kit on his '94 Ram (I have a '98. 5 Ram and also have G1 DSS). I can't answer what is different between his Ram, G1 DSS, and Energy Suspension sway bar kit. His fit, mine did not!

 

[Clinton]

Thanks. Could you PM me or post the info about where you were able to acquire the product? I'm still deliberating on the DSS. I think I'll probably get one, but the frame bushing/bracket isn't what I'm interested in replacing, it's the links. I'd like to get the correct part. Thanks.

 

[John]

I tried to find my receipt/invoice for my Energy Suspension sway bar kit for Dwayne (medicummin) so I could relay the information to him however, I seemed to have misplaced it... temporarily that is. I've purchased so many parts for my Ram in the last six months I have had a hard time keeping everything straight and organized.



I will look for my receipt/invoice when I get home from work.



BTW, the only thing I used from the Energy Suspension sway bar kit was the four urethane end link bushings and the four respective, formed bushing washers. The complete end links are not included in the ES sway bar kit, just the eight parts detailed previously in this paragraph.

 

[John]

Well, sorry guys...

nothing more (worthwhile) to add. I spent at least an hour last night going through each and every receipt for all the accessories and components for my Ram and netted a big fat zilch!



I know I ordered it via the Internet, paid around $20. to $22. for the kit (not including shipping) and I'm thinking I ordered it from Four Wheel Parts Wholesalers in CA.



... I think.



Since I installed the only portion of the sway bar kit I could (in conjunction with the DSS), and that was several months ago, I threw away all the related packaging.



What's weird is...



every time I order something via the Internet I always print out the invoice... just in case.



I guess I just dropped the ball this time. ( )

 

[mediccummin]

Thanks John

for all the help. Ya I called Energy suspension and they said they don't make a kit for our 34mm sway bar, I asked then why does it show 2500 and 3500 for part number 5. 5126 on there web site. He said it does'nt say for Diesel. Then they need to change it to gas only. The numbers on the box the parts came in don't mach the contents of the box or the labeling or the part numbers on the web site or what he told me on the phone. On the box it states kit is for a 94-97 1500 with 30mm sway bar this is kit 5. 5126 but then you open the box and it says on the bushing itself 1-1/4" which is = to 32mm. Any way this is a mess, I'll call Energy again and hope to talk to someone else that knows there own product. And besides I think I won't be able to use these parts anyway because of the DSS like you said. It does appear that there is know way it will fit. OH and another thing the guy from ES told me was the only way to get a 34mm bushing was to reem the one I have out... ... ... whatever. Good luck... ... So bottom line is if you have 34mm bar no such kit, and it you have DSS it does'nt matter because it won't fit anyway... ..... Later... .

 

[Clinton]

I measured mine last night for the first time. My bar is 32mm. That may be why the kits list for 2500 and 3500s. I'm going to order the 32mm kit from 4Wheel Parts and see what happens. My truck is a '96.

 

[mediccummin]

4wheel parts

Hey Clinton I just checked with them a couple days ago and they did not have them in stock... ..... Try Summit Racing they had them in stock ... ... cheaper... ... . free shipping ... ... . and I got them in 2 days... ..... Good luck ... ..... I wonder why your bar is smaller dia. ???

 

[15w40]

I installed the Energy Suspension greasable sway bar bushings on my truck about 4 years ago. The part number is 9. 5165G and it is designed for a 1 ¼” sway bar. This is 32 mm. They fit fine. I decided to put back the stock bushings when I added Darin’s steering fix. The stock “U” shaped brackets are much heavier and fit better with the steering fix.

 

[mediccummin]

thanks 15w40

Unfortunately my sway bar is 34mm. The 32mm would not fit.

 

[Challenger-II]

My '99 2500 is also 32mm. I just received my DSS kit and also have the energy suspension sway bar bushings on order. Anyway that they will fit the sway bar or should I cancel the order??



Thanks!!

 

[John]

Geez...



now you guys are confusing me. Maybe I meant 30mm or 32mm as opposed to 32mm and 34mm. Heck, I can't remember now. I will go home and measure that stupid sway bar again (now that it's really pi**ing me off). This CRS problem I've been having lately is a real PITA.



I believe the smaller sway bar is only for the 1500s. I do know that the 2500s and 3500s share the same sway bar. And I do know I have the larger of the two. I also know I have an Energy Suspension sway bar kit (front urethane blocks and metal retention straps with zerks) in my garage that fit my sway bar perfectly.



Anyway, as 15w40 pointed out, the OE retention straps for the front sway bar mounts are substantially thicker, better made, and formed (for increased strength) than the ES counterparts.

 

[John]

Just Wondering...

mediccummin, are you the original owner of your Ram? The reason I ask is that maybe (if you weren't the original owner) someone either added (assumes no OE sway bar... if that's possible) or "upgraded" the OE sway bar to an aftermarket unit such as a Hellwig or? The diameter of the aftermarket sway bar "could" be larger than what's available from the factory.



... just thinking out load

 

[mediccummin]

John

I'm original owner. I even had the guy from one of the local 4x4 shops measure it with his digital caliper he got 34. 1mm. And I called ES back and they said I'm not the only one that has called about this, others have called that have a 34mm also. ES still says they do not make a kit for 34mm, different guy this time same answers, reem it out. Someone else just posted recently on another thread about there bar being 34mm also, can't find it though. OH well thanks for the info ... ... later.....

 

[John]

OK mediccummin...



I just measured my OE sway bar... it measured 1. 265" which equals 32. 131 mm (don't mind me, I'm a machinist). I thought you were probably the original owner however, I thought I'd just eliminate some possibilities. As I have a '98. 5 2500 QC 4x4 LWB with the 32 mm sway bar, I'm now under the assumption you have a newer Ram... say, '01. 5 or '02? Another possibility I thought of was, is your Ram factory equipped with the snow plow prep. package?



One thing is for sure...



I've seen some weird Rams come from Dodge! For instance, I was always wondering why a co-worker's new (to him) Ram... it's a '01. 5 2500 QC 4x4 SWB, auto. that has always seemed a little low in the front end. High mileage and possible resultant spring sag is not a factor... it had very low miles. Instead, I found it indeed had V-10 front springs*... 38 passenger/39 driver.



* I have two freinds that own V-10 Rams, both with the very same springs



Crap, now after I had my OE 32mm sway bar powder coated gloss black (to match my Ram and everything else... ) I find out that I don't have the biggest, baddest bar available. ( )



LOL

 

[John]

In an effort to regain some of my 1,200 to 1,500 posts I lost a year ago or so during the website changeover, I thought I'd make a separate post ... (heh,heh,heh... there's more than one way to skin a cat) LOL



Actually, I just thought of it (... idea that is).



I don't think reaming out the 32 mm hole in the urethane with a 34 mm reamer will work. The durometer of the urethane is too soft to support that sort of cutting tool effectively (IMO). Probably the best (and most accurate) way to accomplish this would be to mount the bushing to a plate and retain same in a milling vise. The larger hole could be machined by plunging a single point tool through the existing bore (an undersize hole is required to allow for a small amount of bushing crush or preload when tightened). Or, a more crude approach could be to mount the bushing as above and feed the appropriate hole saw through the bore with a drill press. Of course, the vise and table would have to be clamped after finding the center of the existing bushing bore otherwise you could have a real problem.



Another idea would be to retain the bushing as previously described, generating the hole progressively larger with a small diameter sanding drum, say, 3/4" or 1" in diameter. This would be a straight sided sanding drum, tapered sides would only lead to complications. With a die grinder and reduced RPM (you do not want to burn the urethane), progressively rotate the sanding drum around the inside of the bushing bore, periodically checking your dimension (at several different points to ensure roundness of the hole).



And lastly, if you are good with a die grinder and have SHARP carbide burrs (not that you really need carbide... it's just I find they are sharper than their high speed steel counterparts), I would generate the size of the bore out to the desired size. BUT, this would require extreme attention to accuracy otherwise you would ruin the bushings if you went oversize.



Just a few ideas.

 

[Heavy Metal]

Originally posted by Clinton

Thanks. Could you PM me or post the info about where you were able to acquire the product? I'm still deliberating on the DSS. I think I'll probably get one, but the frame bushing/bracket isn't what I'm interested in replacing, it's the links. I'd like to get the correct part. Thanks.

I just replaced the end links on my '01 with Moog parts. Energy only offers the bushings-the Moog kit is the entire end link including urethane bushings. If your bushings are worn out, chances are the ball joint end is shot as well. Regardless, for $35 per side you get the link, bushings, and all hardware. I got mine at Car Quest.

 

[John]

Heavy Metal, I don't mean to be a PITA but, are you sure the insulators (bushings) on the upper portion of the Moog sway bar end links are urethane? I could swear the ones I saw looked like they were made of neoprene (like the OE bushings).



Just wondering