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Here is what parts are needed in order to upgrage your 1980's model 240 sedan from standard swaybars to near-aftermarket turbo bars for a fraction of the cost of buying new.
1. You need the turbo bars (23mm front / 21mm rear) from a salvage yard. Get them from any turbo sedan. (You may also get the FRONT bar only from a turbo wagon. The rear bar on the TW's is same as the standard rear bar you already have)
U-pull-it junkyard Cost: $6.00/ea
2. The needed parts are:
(4) "donut" bushings for the end links P/N 1205991 Cost: $2.61/ea
(2) new part number swaybar bushings P/N 12731840 Cost: $2.63/ea
These new bushings have molded
"ease" in place of the metal tabs
that keep them in place within
the two-piece frame brackets
(2) "braces" and (2) "clamps" P/N 1359391 "brace"
these replece the metal frame P/N 1330185 "clamp"
brackets and are needed for the
newer styled bushings Cost: $11.00/set
Installations tips:
1. Note orientation and reuse metal "cups" from old donut bushings. Discard old donuts bushings. Consider also buying new castle nuts for these link pins. Bentley's says to renew these once you remove them. I did not, so I don't have their part number.
2. Simultaneously, do the following (just kidding :))...
Place the lower metal "cups" and donuts onto the link pins. Hoist up the swaybay and loop its ends over the link pin studs, onto the lower donut bushing/cup. Add the upper donut bushing and its cup. Replace the castle nuts, but don't tighten fully, just enough to hold the bar in place.
3. Use a helper or jack at the center of the bar to lift it closer to the frame, so you can install the backets, bushings and bolts to the frame. Note the approximate position along one side of the bar where the bushing and its bracket set should go to mount up to the frame. Wet the outside of the bushing with soapy water, place it onto the bar with the opening facing to the rear of the car. (At least my original bushings faced the rear.) Slide the deep half of the bracket set onto the long part of the bushing as far as needed to seat the moulded "ears" into the formed receivers in the metal piece. Push the top flap of the bushing down as you do this to assure it surrounds the bar, and is straight with the brace. (not twisted to one side). Install the shorter half of the metal bracket and bolt things up to frame. Use your jack or helper to move things into position.
Note: I needed to use a screwdeiver or rod to help center the bracket holes to the threaded bolt holes in the frame)
I don't know what the torque spec is for these bolts. Probably about 18-25 foot-pounds, I will guess
4. Repeat with the other bushing & bracket
5. Now, go back and tighten the castle nuts on each link pin. I believe the bushing should be squished until it spreads out even with the edges of the metal cups. (I could find no mention of a torque specification for this in Bentley's)
That's it.
Now go enjoy your new ride!
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