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Old 08-08-2008, 05:10 PM   #1
SubieSubie
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Default Front sway bar installed, went for test drive, broke end link!

Man, what bad luck. Got the front bar in, tightened everything down, went for a test drive, made a RIGHT off camber turn, heard a click, the blue thing came flying out from the driver front wheel.
Got home immediately, found that the driver's side endlink is broken! :unhappy:

You can also see that the passenger's side endlink is under stress, probably would have broken off if I had made a LEFT off camber turn.


I hope I'm wrong, that I'm not doing the job correctly, and will gladly apologize to Rallitek, but damn, their parts just don't fit like they're advertised.
Summary: their rear bar had to be forced to line up with the rear endlinks, it was not a passive fit. I'm still worried about something breaking back there.
For the front bar, I could not use their bushings with their brackets. Together they're too thick and would not fit flush with the the mount location. I had to use Rallitek bushing and OEM bracket.
So what should I do now? Buy aftermarket front endlinks? Will they fit the OEM mounting location and line up with the Rallitek bar? I'll be driving next week with effectively no front sway bar.
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Old 08-08-2008, 05:26 PM   #2
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judging at the angle that endlinks sit at, i would go with some WL or other spherical endlinks.

or you can use kb or others with spacers.

my WL and kartboy front and rear line up perfectly without any crazy angles.

and why are they the angles not symmetrical from right side to left? it's like one is acute and the other obtuse?

ok...looks like the bar shifted.
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Old 08-08-2008, 05:53 PM   #3
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You shoulda used the collars supplied with the kit. and you asked about in your other thread. The collars would have kept the bar from shifting and breaking the link. Did the kit not have instructions of any sort? I am confident that they mount is fine with the bushing, maybe you'd better have some experienced help take a look at what you have.
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Old 08-08-2008, 06:39 PM   #4
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maybe your swaybar it upside down, I had a friend do this and snapped an endlink.
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Old 08-08-2008, 08:09 PM   #5
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Quote:
Originally Posted by XmanSTi View Post
You shoulda used the collars supplied with the kit. and you asked about in your other thread. The collars would have kept the bar from shifting and breaking the link. Did the kit not have instructions of any sort? I am confident that they mount is fine with the bushing, maybe you'd better have some experienced help take a look at what you have.
I just noticed the other post too. Definitely have someone take a look at your setup.
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Old 08-08-2008, 08:19 PM   #6
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Luck? Poor planning is more like it. I'd say this is perfectly normal for a heavy duty bar. You're exerting 2-4 times a much force on the links as before and those plastic junk links just aren't up to it. I have Cusco links on the front. They look like OEM links but, they're all metal with a real ball joint in the ends, not a plastic casting like the OEM ones. They're taking the load of my 27mm bar just fine.

I see no sign that the bar shifted. If looks like you went up an off camber driveway or something and the twist of the bar just snapped the link. The angles are what they are because one end is broken and the car looks like it's jacked up so, the lower control arms are angled down.

There's nothing particularly wrong with not having a sway bar. It's not dangerous or anything. Many cars have no sway bars. My old Civic for one.
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Old 08-08-2008, 09:10 PM   #7
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Looks like my not installing the collars contributed to the broken endlink. At this time, do you guys recommend that I get aftermarket endlinks instead of OEM? And which aftermarket units should I consider? Most important are criteria are fit and strength.

XmanSTi: Rallitek only included instructions for the rear bar. They don't have anything for the front.


scby rex: It's highly unlikely that the bar is upside down. The fit it tight with the bar as it is. There's no way the bar can be installed at any other orientation.

MasterKwan: I made a downhill right turn at low speed, maybe around 20 mph, left front wheel dipped down as I drove across a street rain gutter. The photos were taken with the car on level ground, not jacked up.

Thanks guys, I appreciate all your advice/comments.
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Old 08-08-2008, 09:24 PM   #8
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I've upgraded my bars twice and the end links once.

I went from 22mm F&R adjustable WL SB's to 24mm F&R adjustable SB's and have the Kartboy endlinks. I took the car out to an auto-x (my first auto-x) last Sunday and whipped the car. Zero problems.

Additionally, I also have retained the stock rear bar mounting brackets and have zero problems. Only if you have a pre-2004 Impreza do you need to consider upgrading to the 2004+ factory or an aftermarket set of rear bar mounts.

I gotten a good deal of my suspension/chassis/drivetrain parts from Turn in Concepts ("TiC") and recommend that you go to them. They even supplied a set of spacers for the front end links without my having to ask for them. On my 2006 WRX I had to use the spacers. On my friend's 2002 WRX we did not have to use spacers. Each car and each bar is slightly different.

So as you have learned and as a word to those whom choose to upgrade their suspension, you need to look at the upgrade as a part of a whole and you must consider other aspects of what the upgrade might or might not do (e.g. break the factory end links; etc.).

Anywho, get the Kartboy endlinks and go back to having fun with your Subie!

Happy Motoring!
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Old 08-08-2008, 11:00 PM   #9
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Imagine how much grunt it takes to twist that sway bar. Then look at those crappy end links and I think you can see why they snapped. I'm not just making it up. I had a Miata once and I did exactly the same thing. The failure mode was exactly the same. The massive force to twist the larger sway bar simply pulled the end links apart.

Subaru designed for low noise and low maintainance on the stock sway bar and you simply exceeded the specs of the links.
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Old 08-09-2008, 08:42 AM   #10
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I don't think that bar fits properly. It looks to be much too narrow for where the taps on the control arms are.
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Old 08-09-2008, 10:13 AM   #11
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I use Kartboy endlinks front and rear without issues. Although, my Whiteline bar fits much better than the bar you have. The Endlinks line up perfect without the need for washers/spacers. That bar just seems like it's not wide enough.
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Old 08-09-2008, 11:39 AM   #12
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I see what you're all saying. It does look a little narrow.
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Old 08-09-2008, 12:37 PM   #13
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Here's a photo of the 2 bars, do you guys still think the Rallitek is too short? You know how there's not much room in there, and the bar has to be in the correct orientation for the 2 holes to line up with the endlinks. So it's almost impossible to have the bar installed upside down (but it's still possible I guess ). At this time I'm wondering which endlinks to buy, and am seriously considering if I should just get a different brand sway bar as well. But I'll probably do that after getting the new endlinks to see how they fit with the Rallitek bar. Thanks,
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Old 08-09-2008, 12:44 PM   #14
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Guys,

Would these work for my situation?
Thanks,

http://www.rallitek.com/whfrswbaren.html
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Old 08-09-2008, 01:28 PM   #15
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Quote:
Originally Posted by SubieSubie View Post
Here's a photo of the 2 bars, do you guys still think the Rallitek is too short? You know how there's not much room in there, and the bar has to be in the correct orientation for the 2 holes to line up with the endlinks. So it's almost impossible to have the bar installed upside down (but it's still possible I guess ). At this time I'm wondering which endlinks to buy, and am seriously considering if I should just get a different brand sway bar as well. But I'll probably do that after getting the new endlinks to see how they fit with the Rallitek bar. Thanks,
It's pretty obvious from that pic that the Rallitek is much shorter than the stocker. Just seems too short to me.
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Old 08-09-2008, 09:33 PM   #16
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I know from the photo angle it's pretty obvious the Rallitek's is shorter. I'm gonna uninstall the bar and measure both.
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Old 08-10-2008, 01:07 AM   #17
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what does ur rear bar look like. could you have swapped the bars?

Last edited by Zordos; 08-10-2008 at 01:24 AM.
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Old 08-10-2008, 01:31 PM   #18
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Quote:
Originally Posted by Zordos View Post
what does ur rear bar look like. could you have swapped the bars?
I'm pretty sure the rear bar was not installed on the front of the car, and vice versa. For one, each bar was shipped in its own bag, and the tag on the bag indicates which bar it was. Also, the front bar is thicker than the rear, as they should be.

Thanks,
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Old 08-10-2008, 06:07 PM   #19
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yea...rear is all funky and non-symmetrical to go over the muffler. it definitely won't fit on the fronts.

short bar coupled with not using the collars most likely contributed to the failure.

in a proper length bar, not running collars would not cause anything to break.
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Old 08-11-2008, 12:14 AM   #20
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Guys,

I took some photos of the Rallitek bar and OEM bar to show just how much shorter the Rallitek unit is. This photo is a better angle of the 2 side by side.




This photo shows the length of OEM bar to be: 42 15/16. A difference of 1 1/8! Needless to say, I'm gonna contact Rallitek about returning the front bar, probably the rear one too.

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Old 08-11-2008, 12:17 AM   #21
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Here's the measurement of the Rallitek front bar: 41 13/16.

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Old 08-11-2008, 12:24 AM   #22
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Hey subiesubie, I suggest you return the ralliteks. I am running 25mm front and 22mm rear Perrin bars and the fitment is very good. I am running stock endlinks in the front with no issues and it fits perfectly with stock endlinks. The shortness of the bar is putting too much stress on the endlinks.
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Old 08-11-2008, 01:21 AM   #23
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Thanks, that's what I'm gonna do. Just fired off an email to them, and will also call them tomorrow morning.
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Old 08-11-2008, 01:35 AM   #24
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Dupe, deleted.
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Old 08-11-2008, 09:11 AM   #25
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Over at the 3gwrx forums, more people run the rallitek bars then the perrin bars, im surprised no one else had fitment issues.
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