51240 saturn 03 ion rear asb

51240-888 12/05 1 A Division of KW AUTOMOTIVE North America, Inc.

INSTALLATION INSTRUCTIONS

1075 North Ave. Sanger, CA 93657-3539 local: 559-875-0222 fax: 559-876-2259 toll free: 800-445-3767

51240 REAR ANTI-SWAY BAR

2003 SATURN ION 4-DOOR

CONGRATULATIONS! You were selective enough to choose a SUSPENSION TECHNIQUES PRODUCT. We have spent many hours developing our line of products so that you will receive maximum performance with minimum dif-ficulty during installation

Note: Confirm that all of the hardware listed in the parts list is in the kit. DO NOT begin this installation if any part is missing. Read the instructions thoroughly before beginning this installation. Warning: DO NOT work under a vehicle supported by only a jack. Place support stands securely under the vehicle in the manufacturer’s specified locations unless otherwise instructed. Warning: DO NOT drive the vehicle until all work has been completed and checked. Torque all hard ware to values specified. Reminder: Proper use of safety equipment and eye/face/hand protection is absolutely necessary when using these tools to perform procedures! Note: It is very helpful to have an assistant available during the installation process. Note: We DO NOT RECOMMEND using wheel ramps while performing this installation.

RECOMMENDED TOOLS: •Blocks and Wheel chocks •Properly rated floor jacks and support stands •Ratcheting Socket Wrench •Combination Wrench set •Safety Glasses

KIT INSTALLATION 1. Open the hardware kit and remove all the contents. Refer to the parts list (Page ) to verify all parts are present. 2. Park the vehicle on a smooth, level concrete / asphalt surface and put the vehicle in gear or park. Place a block in front of and behind the front wheels. Jack up the rear of the vehicle and place the jack stands in the factory specified locations. Refer to the Owner’s Manual. 3. Using a properly rated floor jack, lift the front wheels of the vehicle off the ground. Place the support stands, rated for the vehicle’s weight in the factory specified locations. Refer to the vehicle Owner’s Manual. Prior to lowering the vehicle onto the stands, make sure the supports will securely contact the chassis. 4. Slowly lower the vehicle onto the stands and, before placing the vehicle’s entire weight on them, again check that they properly and securely contact the chassis as described above. Check for possible interference with any lines, wires, cables, or other easily damaged components.


The following procedure requires the transferring of holes from the bushing brackets and the new Anti-Sway Bar to the Rear Torsion Beam Suspension.

1. TRANSFERRING THE BUSHING BRACKET HOLES TO THE REAR TORSION BEAM A. Center the new bushing bracket on the REAR TORSION BEAM vertically (Photo 1). Using the first lightening hole as a reference, center the bushing bracket to the center of the lightening hole. Measure horizontally from the inside of the round tube area (Photo 2). To the center of the mounting holes on the bushing bracket to the inside of the round tube should be measured at 3 7/8”. B. Using a transfer punch or a marker, transfer the mount holes off the bushing bracket onto the REAR TORSION BEAM. Locate the new mount holes in the center of the slotted holes of the bushing bracket (Photo 3). C. Once you have marked the areas that need to be drilled, with the bushing brackets removed, use a 13/32 drill bit to put four (4) clearance holes through the REAR TORSION BEAM. 2. INSTALLING THE NEW ANTI-SWAY BAR A. Using the grease packet supplied with the new Anti-Sway Bar, thoroughly lubricate the inside of the bushing (Photo 4). B. Install the new bushings onto the new Anti-Sway Bar, locating them in the same area of where the mount holes have been located (Photo 5) Pre-locate the bushings: they will be located just to the inside of the bend of the Anti-Sway Bar (Photo 6). C. Using the 3/8” bolts, mount the bushing brackets onto the bushing and finger-tight only. D. With the bushing brackets mounted, the new Anti-Sway Bar should be hanging from the bush ing bracket, with the Sway Bar hanging down (Photo 7) 3. TRANSFERRING THE HOLES (ANTI-SWAY BAR MOUNT) TO THE REAR TORSION BEAM SPRING SEAT A. With the new Anti-Sway Bar hanging down, rotate the Anti-Sway Bar upward until the ends of the Anti-Sway Bar come into contact with the underside of the spring seat. B. Using a transfer punch or a marker, transfer the holes to the underside of the spring seat (Photo 8). C. Using a 17/32” drill bit, drill a clearance hole through the spring seat. D. Located at this mount, there are two heavy duty washers, per each side, that need to be mounted. The spacers need to sandwich the Anti-Sway Bar, as shown (Photo 9). E. Using the 1/2” mount bolt, finger-tight the bolts.


4. TIGHTENING THE MOUNTING BOLTS A. Using a 9/16” wrench for the bushing bracket mount, tighten to the manufacturers’ specs. B. Using a 3/4” wrench for the Anti-Sway Bar mount, tighten to the manufacturers’ specs. C. The new Anti-Sway Bar should look like this on each end once you have tightened it down to the REAR TORSION BEAM (Photo 10, 11). 5. FINALIZING THE INSTALLATION A. Check that all components and fasteners have been properly installed, tightened and torqued. B. Check brake hoses and steering and other components for any possible interference. C. Lift the vehicle and remove the support stands. Carefully lower the vehicle to the ground. D. Immediately test-drive the vehicle in a remote location so that you can become accustomed to the revised driving characteristics and handling. Be aware that the vehicle will handle substan- tially different now that it has been modified. E. Installation is complete. Check all of the hardware and re-torque at intervals for the first 10, 100, 1000 miles.

51240-300 REAR ANTI-SWAY BAR 1 51025-010 BUSHING 2 51025-005 BUSHING BRACKET 2

112086 3/8-16 x 1” HHCS 4 110625 3/8” FLAT WASHER 4 112318 3/8-16 STOVER LOCK NUT 4 110412 1/2-20 x 1-3/4 HHCS 2 110402 1/2-20 STOVER LOCK NUT 2 110660 1/2” SAE FLAT WASHER 4

2005-007 SPACER 4 55000-110 GREASE PACK 1

PARTS LIST FOR ANTI-SWAY BAR KIT


PHOTO 1

CENTERLINE C L

LIGHTENING HOLE

3 7/8”

PHOTO 2

PHOTO 3

C L

PHOTO 4

PHOTO 5

PHOTO 6

BUSHING JUST INSIDE OF BEND


PHOTO 7

PHOTO 8

ANTI-SWAY BAR

REAR TORSION BEAM

SPRING SEAT

PHOTO 9

PHOTO 10

PHOTO 11

ANTI-SWAY BAR

ANTI-SWAY BAR

51240 saturn 03 ion rear asb

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