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Old 03-01-2004, 02:42 PM   #1
Dynamispeed
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Exclamation *ATTN* Safety issue when using CUSCO rear swaybar on a STI. Please read!!

To anyone using a CUSCO adjustable rear sway bar or their STI (wrx is perfectly fine):

Please be aware that the swaybar can interfere with the lower lateral link and BEND your endlinks. If this happens during a high speed corner it could have disasterous results, as your swaybar will bind your suspension. Luckily we found this out over a speed bump rather than a freeway on ramp or mountain road.


The problem is that the STI endlinks allow hoizontal and vertical play of the swaybar. The cusco bar has no lateral stops so the swaybar can hit the tire. That is the least of the problems. The lever arms are too short and allow the ends of the bar to "toggle"(loud clunk) to the BOTTOM of the lateral link. This effectively lets the swaybar COMPRESS your suspension on one side.

In order to run this setup safely you need endlinks w\ a SOLID bushing on one side (bottom that bolts to the lateral link), and the links also should be adjustable(WRX links will not work). As far as I know there isn't one available. Perrin has one that will be available in a few weeks. The Poltec STI links may work, but still allow too much lateral movement.

I will be working to get a solution to this problem in the next couple days.

Happy motoring,
Ashley
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Last edited by Dynamispeed; 03-01-2004 at 03:29 PM.
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Old 03-01-2004, 03:04 PM   #2
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So that would be why everyone in the suspension forum with an STi was breaking their endlinks with adjustable rear bars over the last several months...
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Old 03-01-2004, 03:08 PM   #3
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yes.. I saw that too. I know people have bought them locally and I dont want to see anyone fly off the road because of a poorly developed and tested part.
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Old 03-01-2004, 03:23 PM   #4
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Hm.. The head guy at Brembo was mentioning something like this to us...

Kym
kym.phan@aerosim-research.com

P.S. Ashley, did you put this up in the brakes/suspension forum?
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Old 03-01-2004, 03:24 PM   #5
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No im going to.
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Old 03-01-2004, 10:14 PM   #6
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FYI, it happens on the 02/03 WRX as well.

I have a set of endlinks from Hairpin Racing. They are pillowball like the Perrins. What happened to me is that the sway bar "walked" over and pulled the bushing out of the endlink.

Hairpin re-installed the bushing for me, and machined me a collar kit that goes around the bar near the mounts that keeps it from moving over. A small hose clamp could possibly do the same thing

Ashley, you may want to post what i did above when you post about the sti thing too
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Old 03-01-2004, 10:39 PM   #7
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Quote:
Originally posted by Kwyjibo
FYI, it happens on the 02/03 WRX as well.
i have not noticed this on my '02 wrx
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Old 03-01-2004, 10:45 PM   #8
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Some swaybars seem to walk more than others. Ive been meaning to fix something around mine but every time I check it, its nice and even exactly where its supposed to be.
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Old 03-01-2004, 10:46 PM   #9
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ps i love you ashley
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Old 03-01-2004, 11:22 PM   #10
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Quote:
Originally posted by vile
i have not noticed this on my '02 wrx
i havent noticed this on my 03 either

-shane
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Old 03-01-2004, 11:35 PM   #11
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This problem is in the STI only, as its lateral links and endlinks are different that a regular WRX.


You may get swaybar walk w\ endlinks that have spherical bearings. They allow too much movement of the bar if you bar does not have a flange on it to keep it from moving. This can happen in any WRX 02-present. It depends on what endlink\bar\bushing combo you use.

At least a moving swaybar does not have the potential to kill you.

Ashley

PS: I love you too Mike
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Old 03-02-2004, 08:09 AM   #12
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Ashley,

The stock sway bar does this as well, it is a fault with the end link design. We have had two STi some in with this problem, they also like to pop the bushings out of the mounts as well.
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Old 03-02-2004, 10:33 AM   #13
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I can see the stock swaybar doing this too.
It is held pretty well (better than the cusco) by the stock bushings from lateral movement. I know a couple people that have had broken endlinks on the STOCK rear sway too.

Ashley
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Old 03-02-2004, 02:39 PM   #14
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yeah i broke my driver side endlink a month ago. Im thinking of getting the progress sway bar or the perrin. Im going to pass on the cusco one for now.
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Old 03-02-2004, 03:13 PM   #15
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I'll be trying a progress bar on a STI soon. I should be a dealer for them shortly.

Ashley
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Old 03-02-2004, 03:39 PM   #16
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Ashley - any updates on this issue/solution. Us with the cusco rear swaybars are eagerly awaiting your update.

sherif
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Old 03-02-2004, 05:08 PM   #17
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Adam from Z1 performance has e-mailed Cusco. Realistically, I don't know what they are going to do about it, or what they can do about it. I could be wrong, but I don't think they have a base of operations here. I'm going to be working w\ Ferdie from South Coast Subaru to at least develop a fix for this.

I think the problem can be solved w\ a set of endlinks that actually hold the ends of the swaybar.

Mabye Subaru can step up to the plate and revisit their endlink design for the STI. This problem has a potential to affect even a stock setup. Mabye they already have for the next model year... I guess we will wait and see.

I'll let you guys know any findings as they happen.

Regards,
Ashley
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Old 03-02-2004, 07:03 PM   #18
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I have an idea for a potential design, but I'm not sure if it would work. In my idea, there is still a weak point being the spherical bushing... hm

please keep us posted & thanks again


sherif
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Old 03-02-2004, 07:18 PM   #19
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thats mine too. A spherical on top and a solid bushing on the bottom.
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Old 03-03-2004, 01:31 PM   #20
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bump
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Old 03-07-2004, 10:26 AM   #21
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So, any suggestion(s) besides the Cusco, or due to the endlinks design this is a "natural" issue no matter what rsb?
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Old 03-07-2004, 12:34 PM   #22
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We took a look at a car earlier this week and we feel that its not something we want to make a patch for. This is a serious problem that Cusco should take care of. Not with some aftermarket link. IMHO.

Tom
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Old 03-07-2004, 09:52 PM   #23
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I snapped one of my stock endlink in half couple days ago. The car drives fine, except for a lot more bodyroll and I am waiting for the Poltec rear endlinks. I think all adjustable rear swaybars will bend stock endlinks, that's a design flaw IMHO.
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Old 03-07-2004, 11:41 PM   #24
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I installed some Poltec's this weekend. They seem to be working ok. I adjusted them longer for some added safety.

Regards,
Ashley
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Old 03-08-2004, 12:03 AM   #25
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I simple fix would be to affix a washer or weld a bead onto the swaybar so it doesn't walk. One on each side of the sway bar should do the trick.

See the bottom bar:

Last edited by mattjk; 03-08-2004 at 12:11 AM.
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