Rear sway bar bracket

[sigchuck]

Hi guys, I'm trying to do what I think should be an extremely simple job - reinstalling my rear sway bar.

I'm running into trouble with the rear bolt in the two brackets - I can get the bolts started but several turns in I hit major resistance. I've checked and rechecked and I'm pretty sure they're not cross threaded, but the last thing I want to do is strip the holes.

I've also checked the bolts and tried all four in each hole with the same result. I've also ran into the same issue regardless of whether I've started the front bolt first and have attempted installing the bolt alone with no bracket or bushing - in other words, it's not a case of the front bolt being too tight or not compressing the bushing enough within the brackets.

Is there supposed to be a great deal of resistance in the rear mounting point?

[917_Langheck]

Porsche PET catalog states that that is an M8 bolt, 18 mm long.

There is no call out of the thread pitch, but maybe it is 1.25 mm - that's the common pitch seen in a google search.

Best thing to do is to check the pitch thread in the bracket side - it's likely to be one of the following; 1.0, 1.25, or 1.5 mm. Given the M8 size, I'm betting on the 1.25.

Then check to see that your bolt matches the same spec's in the catalog. If the bolt size is correct then you may have to chase the threads in the brackets - maybe they are all rusted up given they haven't been in use for some time.

Do any of the bolts continue past just a few threads without any of the rest of the assembly in place - that is, just installing the bolt itself?

[sigchuck]

Interestingly, all bolts thread fine in both of the forward mounting points, but not in the back. From what I recall, the bar was mounted fine when it was removed a few months ago for an engine drop. I’ll try to clean then and maybe a thread chaser as it sounds like something is definitely amiss.

[Locker537]

These are the same bolts that you removed?

[sigchuck]

Yes, same bolts - I actually immediately put the brackets back on loosely with the bolts right after removing the sway bar to avoid any possibility of losing them.

[Locker537]

They have a bunch of old thread locker on them?

[Cory M]

Chase the threads with a tap. Install new bolts too if you want to be thorough.

[cmcfaul]

push the sway bar in place with a jack. Then start the bolts.