Replace the front sway bar end links on a 1966 Chevrolet Corvette to restore suspension performance and eliminate clunking noises during cornering.

Warnings

Tools required

Parts

• Front sway bar link kit (both sides) × 2 — Use OEM specification or equivalent

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. If fasteners show corrosion, spray all sway bar link nuts and bolts with penetrating oil and allow to soak for 15-30 minutes

Procedure

1. 1

   Raise and support vehicle
   Using a floor jack positioned under the front crossmember, raise the front of the vehicle until the front wheels are approximately 2-3 inches off the ground. Place jack stands under the frame rails just behind the front suspension crossmember. Lower the vehicle onto the jack stands and verify stability before proceeding.
2. 2

   Locate sway bar links
   The front sway bar runs horizontally across the front of the vehicle, just behind the lower control arms. The sway bar links connect the ends of the sway bar to the lower control arms. Each link consists of a threaded rod with rubber bushings and metal sleeves, secured by nuts on both ends.
3. 3

   Remove upper link mounting nut
   Using a 9/16" wrench on the upper nut and a 1/2" wrench to hold the link stud, loosen and remove the nut connecting the sway bar link to the sway bar. The link stud may spin if the bushing is deteriorated; apply pressure to keep it stationary while turning the nut. Remove the washer and upper bushing components.
4. 4

   Remove lower link mounting nut
   Using a 9/16" wrench on the lower nut and a 1/2" wrench to hold the link stud, loosen and remove the nut connecting the sway bar link to the lower control arm. Remove the washer and lower bushing components. The link assembly can now be removed completely.
5. 5

   Inspect mounting points
   With the old link removed, inspect the mounting holes in both the sway bar and lower control arm for elongation, cracks, or damage. Clean any rust or debris from the mounting surfaces using a wire brush. Check the sway bar itself for cracks or damage.
6. 6

   Assemble new link components
   Assemble the new sway bar link in the correct order: lower washer, lower bushing (cupped side up), sleeve, then position through the lower control arm hole from underneath. Add the upper bushing (cupped side down), upper washer, then pass through the sway bar hole. Add the top bushing (cupped side up), top washer, and thread the nut onto the stud by hand.
7. 7

   Install and tighten lower connection
   Starting with the lower connection, hold the link stud with a 1/2" wrench and tighten the lower nut with a 9/16" wrench. Tighten until the rubber bushing just begins to bulge slightly. Verify the factory torque specification from the GM chassis service manual before final tightening. Do not overtighten as this will damage the bushing and cause premature failure.
8. 8

   Install and tighten upper connection
   Hold the link stud with a 1/2" wrench and tighten the upper nut with a 9/16" wrench. Tighten until the rubber bushing just begins to bulge slightly. Verify the factory torque specification from the GM chassis service manual before final tightening. The bushings should compress but not deform excessively. Both connections should have equal bushing compression.
9. 9

   Repeat for opposite side
   Repeat steps 3 through 8 for the sway bar link on the opposite side of the vehicle. Both links should be replaced at the same time to maintain balanced suspension response.
10. 10

    Lower vehicle
    Carefully raise the vehicle slightly with the floor jack to unload the jack stands, then remove the jack stands. Slowly lower the vehicle to the ground. This allows the suspension to settle to normal ride height with the new links installed.

Reassembly

1. Ensure both sway bar links are installed with bushings properly oriented (cupped sides facing the washer)
2. Verify all nuts are tightened evenly with similar bushing compression on both sides

Verification

• Bounce each front corner of the vehicle and listen for any clunking or rattling from the sway bar area
• Visually inspect both links to confirm bushings are compressed evenly and nuts are secure
• Test drive the vehicle at low speed over uneven pavement and through turns to verify the sway bar links are functioning properly and no noise is present

More procedures for this vehicle