Hey all -

Did sway bushing in the rear today and decided to move up to the fronts. Had the Energy Suspension 9.5161G's ready to go. The front links are new, so I was just trying to do the sway bar mount bushings. Old material was squashed flat and torn on both sides.

So, I popped the old off, and put the new on.. only, it wouldn't fit (about a quarter inch gap). They fit perfect on any other part of the bar (like the straight center area), but on the passenger side (only side I tried), it simply won't fit. The bar doesn't seem rusted, and definitely isn't repainted, but it's lumpy. Whacked it with a wrench expecting it to be a rust bubble, but nada.

I don't know if it'll close completely with the metal bracket on top of it, as I bought the wrong freaking bolts today, but the factory bracket won't fit back over it when on the bar, otherwise fits acceptably with both pieces off truck.

Going to Moab next weekend with a 5.5hr drive ahead of me so I'm kind of apprehensive about running without a front sway bar that whole time. Also going to camp and light offroading, so wild flexing isn't the priority. Has anyone else experienced this? Should I buy a new bar entirely? I guess I'd hate to commit to being swayless up front forever since I just installed new front links like 1k miles ago.

Thanks for ideas, will try to snap some pictures tomorrow. And just to reiterate, the 9.5161G kit is correct for the bar, and the fit is perfect anywhere but where it needs to be

I had the same problem with mine I just ground down the radius, so the metal sleeves fit

Post a pic ....

I'd be surprised to see it is really bent. The sway bar is (I think 3/4") solid steel and it would take a hell of a lot of force to break it or bend it. I would say probably more force than almost any normal offroading.

At work but I'll try to snap one real quick and post this evening. This is pretty much what it looked like, I guess lumpy is a better description... or deformed. Certainly not perfectly cylindrical like other parts of the sway bar.

Here's an artistic representation

Gonna give it another shot wednesday morning. Found the right size bolts and nuts, just not grade 8. Want to make sure they get the job done size wise before seeking the proper hardware, and only cost a few bucks tonight at Home Depot.

Question - I've read a lot from people who run no sway bar up front even on the road, and get along okay. I figure my situation will be temporary (I really want to not have wasted $ on my new front links), but what all do I disconnect if I commit to going this route?

So many people say things like "I removed it all together", but for a quick fix, do I just undo the two brackets holding it underneath the vehicle, or do I just undo the bottoms of the links, or the top bolts of the links.. or what.

Thanks will continue to peck around in threads looking for answer.

If you are going to leave it out remove the brackets and take the entire bar and both links out. You don't want that stuff rattling under your runner for your Moab trip. If I were you I would drive around with it out and decide if you are willing to deal with that setup all the way to UT.

I will never put my front back in, but my rig sees 80% dirt and doesn't have stock suspension up front.

Thanks man, was thinking it wouldn't seem right to have bits and pieces disconnected only for it to slap in to other things. 4runner only became my DD when I decided I'd be selling the tacoma (and trying to keep miles off of it). Daily commute is like 8 miles round trip @ 35mph speed limits (Denver). I do have to go up to Fort Collins tomorrow so I'll disconnect everything bright and early and head up there, though that's basically a straight shot up i-25.

Gotta do Moab the weekend after this upcoming due to no dog sitter (dog is ancient, couldn't handle camping) so I'll have a good trial period before the big journey.