Important info for all those with aftermarket sways!

[J-Ro]

Hey everyone,

I made a startling discovery today





That's the left side arm and endlink. As you can tell from the condition of the break, it's apparently been like that for some time, and obviously I didn't hear it go.
After I inspected the break a little more closely, I believe that increased stress in the bracket from the Progress swaybar causing a hairline break to form, which only went downhill from there. It's not very easy to see from the pictures above, but after looking at the piece that came off with the endlink, I could tell that the first crack started on the outboard (towards the wheel) side of the car, migrated around, and finally split the inboard side.

Fortunately, I was able to fix it. I welded the piece back in with a MIG, ground it flat again, and welded heavy gauge 5/16" washers on BOTH sides. After grinding them flat as well, I drilled the hole back out to 10mm and painted it black. I also did the right side, so that they are both equally reinforced.



So now I have the problem fixed, and the bracket has now been heavily reinforced, so this should prevent it from happening again--although I can't say for sure at this point...
Also, I will be switching out the stock endlinks (hopefully tomorrow) for the Corsport V2 ones, so those components will be upgraded as well.

I just thought I'd make everybody with aftermarket sways aware of this potential problem, and to let you know that it is fixable/preventable

Jason

[Zeuceone]

ill have to keep an eye on mine. thanks

[rippars]

now before it broke did you ever experience any noises or anything while the car was at tweaked in any shape or form (inclines, and etc.)?

[Zeuceone]

you should of felt the dif. after it broke.

[J-Ro]

When I think back, I think it may have happened a few days after I got hit by a chunk of ice (big insurance nightmare)... it was also the middle of the winter, so that's probably why I didn't notice it.

[cojaro]

One of two things:

1. factory parts may not handle really think rear sways well, or

2. your bracket had a minor flaw (composition off a little, etc) that caused the break

Hopefully it's number 2

[USDM-FG2]

Holy Crap that sucks... Think you could use JB weld as well? Cause some of us dont have access to a welder

[J-Ro]

Originally Posted by USDM-FG2

Holy Crap that sucks... Think you could use JB weld as well? Cause some of us dont have access to a welder

No idea... I wouldn't trust anything less than welding it because of the stress that joint takes. Also, I added more material to it because I didn't just want to fix it, I wanted to make sure it wouldn't happen again.

[eugenekim.net]

ahh scary

[atruhondagrl]

Thanks for putting that info out there though. Could definitely come in handy at some point.

[rippars]

it might just be me but i get a popping sound when taking inclines... still on the stock endlinks and i do have the hotchkis endlinks i need to install. one of the bolts that hold the sway in place by the bushings snapped and i recently got a new bolt in place and greased everything again with white lithium grease and didnt have any issues til today (it was about three weeks ago now.) granted i should have taken the incline a bit more slower than i did but i was going pretty slow already. if anyone has any input im dropped on eibach prokits as well.

[SiRyan]

OMG! I'm going to check mine right now! Thanks for the info.

[lonelydriver]

Originally Posted by cojaro

2. your bracket had a minor flaw (composition off a little, etc) that caused the break

I think it is not a flaw and I'm pretty sure that the bracket cannot handle a larger sway bar due to stress. The TSX also has this problem too when it is paired with a Progress sway bar and it ain't pretty.

[J-Ro]

Originally Posted by lonelydriver

I think it is not a flaw and I'm pretty sure that the bracket cannot handle a larger sway bar due to stress. The TSX also has this problem too when it is paired with a Progress sway bar and it ain't pretty.

It's probably not what anyone wants to hear, but I think you're probably right. An aftermarket swaybar will definitely increase the stress levels in those brackets... using adjustable endlinks that are adjusted to remove preload will help, but won't relieve the stress once you're in a turn.
With those extra washers in place, I've almost tripled the material thickness around the mounting holes on the arm, so I'm hoping that will keep something like this from happening again.

Originally Posted by rippars

it might just be me but i get a popping sound when taking inclines... still on the stock endlinks and i do have the hotchkis endlinks i need to install. one of the bolts that hold the sway in place by the bushings snapped and i recently got a new bolt in place and greased everything again with white lithium grease and didnt have any issues til today (it was about three weeks ago now.) granted i should have taken the incline a bit more slower than i did but i was going pretty slow already. if anyone has any input im dropped on eibach prokits as well.

If this sound is recurring, I'd probably say that it's not the end brackets for your swaybar. If the bracket is going to break like mine did, it'll pop once and that'll be it. But you mentioned that you had problems with the mounting bolts for the sway... maybe a bolt stripped or something and is "popping" in/out of the hole when the sway rotates? Not sure... it's odd that it's a recurring sound.

[stevediehlman]

Thats funny because the links are "supposed" to be the weak part and "should be replaced". Looks like the links are fine.

While on this, has anyone broken a stock link?

[DumbasSi]

OUCH! Just be glad it wasnt the subframe where the swaybar bolts to the underside of the car. THAT would be ugly. I guess the LCAs are the weak point.

On the older 96-00 Civics, many people upgraded to a Type-R or big aftermarket bar. They were usually too stiff and tore the subframe apart. Now, companies like ASR make reinforcement kits to strengthen the subframe. Maybe the 06+ Civics need something similar to handle the stress of the stiffer bars.

[1stk20z3]

holy crap thts f'ed up man!glad u fixed it!

[bossman]

Yes..good info,I hope this is an eye opner to everyone that is considering larger bars.I for one wil make sure this is taken car of before installing a big rear bar.

[J-Ro]

Originally Posted by bossman

I for one wil make sure this is taken car of before installing a big rear bar.

For sure... the right side bracket was fine, but I strengthened that one as well. If you have a welder, or know someone who does, it's an easy fix for a potentially big problem.

[dt07Si]

Hmm thanks for sharing this with us.

My last car was a '98 GSR and like DumbasSi said, when a larger rear sway bar was installed on some older Civics and also 94-01 DC and DB Integras (with the exception of the ITR) they were prone to sub frame tear outs and needed to be reinforced at the sub frame prior to installing an aftermarket rear sway bar.

I am still waiting for my Progress bar because its on backorder right now and I haven't gotten under the rear end of the car and taken a good look at everything but I'm surprised the tear out was on the LCA.