Broken Sway Bar

Broken Sway Bar

Postby GuyS [OP] » July 13th 2019, 9:42pm

SwayBar.jpg
Although the photo suggests it had been broken for a while (the rust looked pretty deep), I had had the shocks replaced only 800 miles previously and the sway bar was not broken then.
Started hearing weird clunks in my 05 Astro. The noise would sometimes occur turning sharp (like backing into my driveway) and sometimes over speed bumps. It turned out to be a broken sway bar. The "V" break could have something to do to the torsion stress on a sway bar. Just sharing.
Last edited by GuyS on July 13th 2019, 9:53pm, edited 1 time in total.
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Re: Broken Sway Bar

Postby GuyS [OP] » July 13th 2019, 9:52pm

Here is a photo I took of a leaking shock that prompted me to replace all shocks on the van 800 miles before the sway broke. You can see in the photo the sway bar was not broken then.
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Re: Broken Sway Bar

Postby M_a_t_t » July 14th 2019, 2:12am

The ends are a common failure point. I think you can order a solid sway bar for a cargo for a direct swap.
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Re: Broken Sway Bar

Postby GuyS [OP] » July 14th 2019, 2:19pm

The sway bars seem to be readily available. Mine was in Vancouver BC
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Re: Broken Sway Bar

Postby M_a_t_t » July 14th 2019, 4:08pm

I know passenger replacements are available, but the cargo replacement was solid and since they share subframes and suspension parts it should be a direct swap. Solid = less likely to break + better feeling around curves
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Re: Broken Sway Bar

Postby GuyS [OP] » July 14th 2019, 4:28pm

You know I searched through a few posts here and it seems that the hollow ones were factory. The solid ones are all that is available now. I am not sure but is there a difference between the sway bars that are on cargo vs a passenger Astro/Safari?
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Re: Broken Sway Bar

Postby Leeann_93 » July 14th 2019, 4:58pm

Sway bars are all the same design/dimensions. Factory is hollow, aftermarket are all solid. The hollow bar is weak at the flattened area and always rusts and breaks there.
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Re: Broken Sway Bar

Postby e7ats » November 21st 2019, 3:51am

I had about 110K on my swaybar when I noticed it cracking just behind the flat part. I purchased my swaybar from NAPA and it was a solid bar.
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Re: Broken Sway Bar

Postby smokinjoe » November 24th 2019, 10:10pm

I got beltech solid ones front and back & It handles like a camaro now.
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Re: Broken Sway Bar

Postby petema » September 16th 2020, 1:15pm

Welded the front sway bar today. One side was slightly split and the other more so, a piece fell of when removed. There tends to be some rust inside the bar, moisture enters the bar trough a small hole on each side, an inch or two from the drop link. REMOVAL of the bar was surprisingly easy once the idler arms where loosened and swung backwards. Using a pneumatic tool for bolt removal saves a lot of time. Drop links where renewed. Best way to remove them is by grinder, they are hardly reusable anyway. Pulled the worn half axle and put in a good regreased one with good rubber. The axle was originally the sole intention of the job, but you know how it is once you go ahead with something.
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Re: Broken Sway Bar

Postby MechBob » September 17th 2020, 5:43am

So,petema,I hope you consider this a temporary repair?Besides,if you install a solid bar you would be amazed.
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Re: Broken Sway Bar

Postby petema » September 17th 2020, 8:42am

Thanks for your advice MechBob. With the availability of parts for the Astro, there is no good reason to wait for total breakdown until a new part is installed. P
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Re: Broken Sway Bar

Postby markmitch » September 17th 2020, 2:46pm

The solid ones are /were a higher tensile strength and were as ordered from GM My 89 has the factory solid bar with GM stickers on it so they were available from GM at one point.
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Re: Broken Sway Bar

Postby augidog » September 17th 2020, 3:44pm

MechBob wrote:So,petema,I hope you consider this a temporary repair?Besides,if you install a solid bar you would be amazed.
I know I was. my original hollow bar had become permanently twisted about 1"...my Dorman solid replacement kit is one of the best investments of time & money I've made, in my opinion.

here's a tip I learned when looking at my original links. they were still plastic-wrapped, and I realized it for easy assembly. I taped my replacement hardware together into easy-to-handle packs, and there was no searching for, or juggling of, washers and bushings, and zero cussing, while laying on my back under the van.
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