Suspect bent sway bar?

DANIEL JAMES MATTINGLY

MEMBER
2005 DODGE CARAVAN
3.3L
6 CYL
2WD
AUTOMATIC
150,000 MILES

I was changing my failing sway bar links, and when I changed the second one on the passenger side, I had an anomaly that was different from the driver's side link. Firstly, I noticed that when I was unscrewing the nut on the top one that there seemed to be pressure on the bolt and it was being pushed upwards, and the same thing happened with the bottom bolt to the extent that the bottom link fell apart, with the ball popping out of it's socket. I had to hammer out the link bolts and as I did the sway bar bounced up, leaving a too small of gap for the new link to fit. I had to use a large prybar to bend the sway bar down far enough for the link to fit. I suspect that the bar is bent because also I changed the sway bar bushings a little while back and that passenger side one is already reamed out. I'm suspecting furthermore that the bent sway bar will wear out that new sway bar link I put in fairly quickly because of the excessive pressure on the link pushing the upper bolt upwards and the bottom bolt downwards. I know that it is a fairly rare thing to happen to spring steel, perhaps the previous owner got into a serious accident with it and failed to report that to me for whatever reason. Does what I describe sound like a correct assessment?

5 Replies

KEN L

MASTER CERTIFIED MECHANIC
47,643 POSTS

Yes, it is rare for this to happen, can I ask if when you were doing the work, was the front end off of the ground (bother tires)? You may have a strut that is not releasing fully, I would disconnect one of the sway bar links and lower the van to see if the front tires touch the ground at about the same time and if not inspect the front struts for leakage and replace as needed. Please upload a short video of the problem is I can see what's going on.

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Thursday, January 26th, 2023 AT 11:59 AM

DANIEL JAMES MATTINGLY

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3 POSTS

No, I jacked up my van one side at a time. I'm pretty sure it's not the strut as I could visibly see the sway bar bend up and it looked like it was in a different position than the driver's side, plus there's the reamed-out sway bar bushing on the passenger side too that I painstakingly put in last summer.

I've done the bounce test on the struts, and they seem to bounce once and rest like they should, no noticeable binding in the them, although they do look tired, and I will need to change them soon. I can't afford to throw parts at it and get the diagnosis wrong, let alone the time allotment for it to get worked on, as I have two kids and work full time.

I know that it's rare but is it totally unheard of to have a bent sway bar? That link will probably wear out fast, they're $125 a piece here on Saltspring island, I ordered two online for $18 each and they took almost two weeks to get here, so it's hard for this home mechanic.

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Thursday, January 26th, 2023 AT 1:45 PM

KEN L

MASTER CERTIFIED MECHANIC
47,643 POSTS

I have seen bent sway bars before yes, but if one jack it up one side at a time it will load the sway bar, if you can see the bar physically bent then there is no question. Here are instructions on how to replace it. Check out the images (below). Let us know what happens and please upload pictures or videos of the problem.

Images (Click to make bigger)

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Thursday, January 26th, 2023 AT 5:34 PM

DANIEL JAMES MATTINGLY

MEMBER
3 POSTS

Thanks for the reply, Ken, I really appreciate it. I hear you on the jacking up the one side possibly being the issue, I will have to jack the front up with both wheels off the ground and also get some pictures. I think that because the old links ball joint on the suspect side was also bent from pressure on the top and bottom bolts, and that the sway bar bushing is reamed on that one side, that either the strut is binding like you said and not releasing properly, or the sway bar is truly bent. Also, when you suggested undoing one sway bar link and lowering the vehicle to see if the tires touch at the same side, why only one link undone? I would think that you'd have to undo both links. Can you please explain? Cheers.

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Thursday, January 26th, 2023 AT 7:14 PM

KEN L

MASTER CERTIFIED MECHANIC
47,643 POSTS

Once one link is undone the sway bar is unloaded so you can tell the different height of each side without the sway bar trying to correct the level. Pictures all help if you can, that would be great.