Ordered new front and rear Energy bushings from 4 Wheel parts, came in yesterday. The catalog says the front sway bar bushings are 24mm, but these things aren't even close, my front bar is several sizes bigger. I checked several different auto parts sites that carry Energy bushings, and they all list 24mm for my ride.(95 4WD, auto) What's up with that?

From a quick google search, it seems that 24mm is the stock size. Next thing I would do is measure your sway bar, maybe it's not a stock sway bar? Also, measure the bushings that they sent you. Maybe they sent you the wrong bushings?

I measured the bushings when they came in, and they are indeed 24mm front and 18mm rear. Stupid me, I didn't measure my sway bars, I relied on the measurements in the catalog, how stupid do I feel.

Did some checking, and it appears that some of the 95's may have 27mm bushings, and all of the 96's had them.

Meh, happens. I rely on catalog info when I order stuff.

Watch out with Energy Suspension. I ran into the same problem with my 94. Anyways, it turned into a big issue to return the front ones since they were part of the Master Kit. They wanted me to send back all the control arm bushings too, which I had just spent the weekend getting on the truck. Eventually, they agreed to send a set of 27mm that I think were for 3rd gen t4r, but those didn't fit either. They fit around the sway bar itself, but not into the factory bracket. Long story short, I really like the ride improvement and better handling from all the bushings, but I never got the right size for the front sway bar and had to pay for return shipping two times before I gave up with it and went to the dealership for Toyota ones.

Just a follow up to this thread, I called up Energy tech line to ask about the 24mm bushings. He basically told me that if the catalog says they should be 24mm, then they are 24mm. And if the swaybar is bigger, measure it and we
will replace with the correct size, huh?

So I went to my local Toyota parts counter(they are very good, if not more
than a bit overpriced), my parts guy looked it up, said stock bushing is 27mm
on the 95 4Runner. Asked him about variations or other sizes, he looked at me
funny and said, there is one bushing size, and it is 27mm, that's it.

What in the world is up with Energy?

I dunno denial I guess. Be wary of them. I like their product. Actually could not be happier with what the control bushings did for my rig, but their customer service seemed lacking... You would think its easier to include the right bushing in the kit for the start. I can't imagine us two are the only ones who have had a problem with it.

You need to mic all the stuff out before ordering. I did this with our 1990, which had larger then stock bars(had some handling or off road pkg). Then replaced all of the bushing with Energy Suspension units and have been very happy with the results over the years. The guys over there were great.
The only things I would recommend is mixing and anti-seize compound with M1 synthetic marine grease to lube up the bushings. This will keep them lubed up for years to come.
regards