Sway bar end link bolt diameter? Mine are too small..

[GreenBravada]

Hi. Sorry if this question has been asked and answered before, but I don't see it.

I am rebuilding the front suspension on a completely STOCK 2003 Bravada with factory TOW package. Among the pieces I was replacing (no noise from them but the rubber boots are gone) are the sway bar end links. I ordered some Chinesium end links that specified my Bravada, and the diameter of the bolts is definitely SMALLER than the bolt holes in the sway bar and chassis. They also are a different LENGTH than the ones I removed. So, I went to the MOOG site, checked the applications and ordered right and left MOOG links. They arrived today, and the bolt ends are the same SMALLER diameter than the ones removed from the Bravada.

What's up with this? Are there end links specifically made for the TOW package? Why are they not called out somewhere?

If i put these small diameter links on in the big holes, they will move up and down.

Advice, please.

This is one of the Moogs that I received today. Bolts are smaller diameter.

 

[Mooseman]

More than likely, the holes have been egged out. Happened to me on my EXT. I noticed that the ACDelco links came with a hardened washer to use on the back (joint) side of the stud but not any of the aftermarket ones. Mine were so egged out that they kept getting loose so I made sure to use the washer and torqued the crap out of the nut with some red Loctite. It's been a long time but I might have also welded up the hole and re-drilled it but I would have still torqued it to hell.

 

[movietvet]

Yea, I looked at RA and all looked the same and I was surprised that RA did not list a sway bar assembly. Not that that would address the other end of the link but I had to look.

 

[GreenBravada]

Nope! Both new end links have 12mm diameter "studs" while the ones that came off the truck were larger, maybe 13 or 14mm. So the hole would be too big even if the hole was not egged out. The hole is taller than it is wide, as you'd expect from wear or looseness.

I found some steel spacers that are 1/2 ID and 5/8 OD. I may end up drilling out the holes to 5/8" and putting the spacers around the bolt and through the new holes. Might also largely solve the egging out distortion.

Lastly, I have to decide whether to use the Moog parts I just got and write off the Chinesium ones. Those came in a set for front and back for about $46,

 

[GreenBravada]

Yea, I looked at RA and all looked the same and I was surprised that RA did not list a sway bar assembly. Not that that would address the other end of the link but I had to look.

I have a suspicion that the 2003-2004 Bravada may have been just a touch "softer" or "cushier" than the GMC and Chevy versions. There may have been model specific end links for a softer ride but no one bothers to make them anymore.

I just searched Moog for 205 Buick Rainier (continued Bravada) and came up with a different part number:

 

[Mooseman]

Those things are under a lot of tension whenever you are turning. Probably one of the reasons the holes get egged out. I wouldn't put much faith in the Chinesium ones. When I got the EXT, it had Moogs all around and I had to replace them a couple more times. I think I ended up with ACDelcos. My '07 is still on the originals at 210K km.

Factoid: These end links were so problematic, the engineers changed the front ones to good ol' fashion rubber bushings and bolt type in 08-09, just in time for the end of the platform.

 

[GreenBravada]

I think this is the key to my mystery. On the left is the link at Moog for the Buick Rainier and the one on the right is what is being sold as compatible with all 360 models. My eyes may be deceiving me, but the Buick part looks like it has larger diameter bolts. Also, Moog only lists the LEFT side as being available. Maybe they don't any longer make or stock any of the right hand ones.

 

[Mooseman]

Don't look beyond 2005 because the sway bar was changed on 2006+, being captured inside the frame rails with different end links.

 

[GreenBravada]

RockAuto listing for 2005 Buick Rainier

 

[Mooseman]

The one on the left looks like it has a longer shaft. That could come into play if the Bravada/Rainier has a lower ride height.

 

[GreenBravada]

Just to further show that not all models had the same end links, here's the compatibility description for some cheap version of the Buick end links:

K80824 K80825 2Pcs Front Sway Bar Stabilizer Link Compatible With Buick 2004-2007 Rainier/for Chevy SSR Trailblazer/for G-MC Envoy/for Isuzu 2004-2008 Ascender/for Saab 2005-2009 9-7X​

 

[Mooseman]

Don't look beyond 2005 because the sway bar was changed on 2006+, being captured inside the frame rails with different end links.

Never mind what I said there. Despite the different sway bar, they used the same links from 02-09

 

[GreenBravada]

The one on the left looks like it has a longer shaft. That could come into play if the Bravada/Rainier has a lower ride height.

Very true, and they ones on my truck are different length than either of the replacements. Well, now I know what parts I need. Thanks to all for helping me sort this out.

 

[Mooseman]

Just to further show that not all models had the same end links, here's the compatibility description for some cheap version of the Buick end links:

K80824 K80825 2Pcs Front Sway Bar Stabilizer Link Compatible With Buick 2004-2007 Rainier/for Chevy SSR Trailblazer/for G-MC Envoy/for Isuzu 2004-2008 Ascender/for Saab 2005-2009 9-7X​

And they don't have the washer. I think that's the difference in egging the hole or not.

 

[GreenBravada]

Thanks to all for helping me sort this out. You guys are the BEST.