Chassisworks 5806-U10 User manual

Description: Splined-end anti-roll bar for custom-fit applications. Designed for use with g-Bar/g-Link
canted 4-bar and torque arm rear suspensions. Assembled bar width 32” to 43”.
Includes: 3/4” diameter bent-tube anti-roll bar, billet-aluminum arms, pivot tube adapters, pivot
sockets, endlink assemblies, and frame tabs.
Notes: Threaded mounting socket is part of lower axle-housing bracket and ships with g-Bar
suspension system. Bar assembly and installation of chassis tabs requires welding.
INSTALLATION GUIDE
5806-U10
g-Bar Splined-End Anti-Roll Bar
for Custom-Fit Applications
Chassisworks
Chassisworks
CHRIS ALSTON'S
CHRIS ALSTON'S
THE HOME OF HIGHER TECHNOLOGY
THE HOME OF HIGHER TECHNOLOGY
READ ALL INSTRUCTIONS COMPLETELY AND THOROUGHLY UNDERSTAND THEM BEFORE DOING ANYTHING.
CALL CHASSISWORKS TECH SUPPORT [phone] IF YOU NEED ASSISTANCE.

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PARTS LIST
Prior to beginning installation use the following parts lists to verify that you have received all
components required for installation.
Mounts and Hardware - 300-0197
Qty Part Number Description
2 1086 Adjuster rod 3/8-24 x 3”
2 1162-0.495 Ballend tube adapter
2 1262 Lock ring 1-7/8-20
2 1468 Billet anti-roll bar arm 1-1/4” 48-spline
4 2121 Clevis tab 3/8” hole
4 3100-038F1.50Y Bolt 3/8-24 x 1-1/2 hex head Grade 8
4 3101-038-24C Locknut 3/8-24 nylon insert
2 3102-038-24LY Jam nut 3/8-24 LH Grade 5, yellow zinc
2 3102-038-24RC Jam nut 3/8-24 RH Grade 5, clear zinc
2 3103-038C1.75C Allen head 3/8-16 x 1-3/4 socket head cap screw
2 3108-038H-C Lock washer 3/8 high collar
2 3108-038L-C Lock washer 3/8 regular
4 3109-038-S-2-Y Aircraft washer 3/8 small OD
2 3111-038X038-LT Rod end 3/8-24 LH x 3/8 bore
2 3111-038X038-RT Rod end 3/8-24 RH x 3/8 bore
2 3157-038F-C Fender washer 3/8 x 1-1/2 OD
2 3701 Preload adjuster assembly 1-7/8-20 thread
Splined-End Anti-Roll Bar - 5806-U10
Qty Part Number Description
1 4765-21 Anti-roll bar 3/4” diameter x 37.35” overall length
1 300-0197 Mounts and hardware

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INSTRUCTIONS
Anti-Roll Bar Welded Assembly
Anti-roll bar splined tube adapters must be correctly indexed to one another when welded.
1. To determine correct tube length, measure the inside width of the axle brackets and subtract 6-1/8
(6.125) inches.
2. Drill a 5/16” hole through both walls of the anti-roll bar tube 1/2” from each end. These holes will
be used to rosette weld the splined adapters to the center tube.
3. Insert one of the splined adapters into the center tube. Weld the holes, filling the hole from the
adapter to outer surface of the tube. This is a rosette weld. You can now weld the circumference of
the joint. This needs to be a good quality weld.
4. After the weld is completely cooled, slide the first billet arm onto the adapter. Position the arm with
the pinch-bolt head up. Secure arm with a socket head cap screw and high collar lock washer.
5. Slide the second arm onto the loose adapter with pinch-bolt head up, then tighten the bolt.
6. Insert the second splined adapter with arm attached, into the anti-roll bar tube. Set the assembly
on a flat surface with both arms forward. This will index the splines and keep the billet arms flat to
each other.
7. Rosette weld the second splined adapter to the center tube through both holes. Once the rosette
welds are complete, remove both billet arms and weld the circumference on the second joint. This
needs to be a good quality weld.

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Anti-Roll Bar Assemby
Anti-roll bar must be assembled
to correctly position bend
for maximum center section
clearance.
1. Place billet arms and anti-roll bar
on a flat working surface. The
arm’ bolt counter-bores should be
facing down.
2. Orient the anti-roll bar with the
bend pointing the opposite
direction that arms extend.
3. Rotate bar approximately 45
degrees, so that bent section is
raised and insert a splined-end
into the first arm until the splines
are slightly engaged.
4. With the inserted arm laying flat
on the table, raise the opposite
end of the bar and slightly engage
the splines. Make sure the arms
are indexed the same so that they
are flat to each other.
5. When correctly indexed, the top of
the bend should be approximately
2-1/2 to 2-5/8” from the working
surface. If the bend height is
outside this range, disengage
splines, rotate bar, reassemble,
and then measure again.
Note: Assembly orientation
is upside down from actual
installation orientation.

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6. Secure arms with 3/8-16 x 1-3/4”
socket head cap screws and
high-collar lock washers. Use a
small amount of Locktite® on the
threads.
Note: This pinch-bolt configuration
applies pressure against the
spline to remove all play.
Preload Adjuster Assembly
Following photos shot with bolt-on
style axle brackets. Installation
procedure is identical.
7. Make sure 1-7/8” female threads
in lower axle brackets are clear
before begining assembly. Use
a wire-tooth brush in a rotating
motion to clean the bores. The
fine thread is easily siezed up by
debris or powder-coat residue.
8. Apply a small amount of Anti-
Seize to the external threads of
the preload adjuster assemblies.

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9. Using a 1/2-inch drive ratchet
and extension, thread the preload
adjuster assemblies into the
threaded sockets on the lower
axle bracket. Continue until they
are even with the socket edge
closest to the rearend center
section. Do not forcefully thread
the assembly together. Doing so
will damage the threads.
10.Place the anti-roll bar assembly
between the preload adjusters
with the arms toward the front of
the car and the pinch-bolt heads
facing up.
11. Continue to tighten both adjusters
evenly until the ball end of the
anti-roll bar is bottomed out
against the bearing.

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12.Verify that the anti-roll bar is
centered. Billet arms must be
equal distance from the axle
brackets. Then, tighten both
preload adjusters an additional 1/4
turn. Do not overtighten. Doing so
will cause the anti-roll bar to flex.
13.Thread the locking ring into
the axle bracket socket so that
it is tight against the preload
assembly.
14.Secure with 3/8” fender washer,
lock washer, and 3/8-24 x 1-1/2”
hex bolt.

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15.Tighten to 35 lb-ft.
16. Repeat steps for opposite side.
Endlink Adjuster Assembly
17.Thread 3/8”-24 jam nuts onto
each rod end until 3/4” of threads
have passed the jam nut. This
will position the jam nut at
approximately half travel. Yellow-
zinc jam nut indicates left-hand
threads.
18.Thread the endlink adjuster tube
onto the rod ends. Hex end of
the adjuster indicates left-hand
threads. Do not force threads.
Run a tap through the adjuster if
necessary.
19.Attach the endlink adjuster
assemblies to the billet arms. Use
3/8-24 x 1-1/2” hex bolts and lock
nuts provided. Torque mounting
hardware to 35 lb-ft.

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Clevis Tabs Installation
(Weld-In)
Images were shot using a folded
clevis with bolt spacers. Individual
tabs will seat directly against rod
end.
Install rearend housing in the car
at ride height before proceeding.
20.Find a suitable location along
the frame rail or crossmember to
install the clevis tabs.
21.Temporarily install the endlink
using the 3/8” bolts and locknuts.
22.Position the clevis tabs against
the mounting surface and tack
weld the tabs in place.
23.Repeat procedure for opposite
side of vehicle.
24.Check for any clearance issue
with the anti-roll bar throughout
the suspension’s range of travel.
This must be done without springs
installed on the shocks or without
air pressure if using air-spring
shocks.
25.Unbolt the endlink assembly from
the clevis and weld completely
around the tabs.
26.Spray paint bracket and weld area
to protect against rust.

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27.Install adjuster link assembly into frame mounted bracket.
28.Torque mounting hardware to 35 lb-ft.
29.Adjuster links should be in a neutral position, meaning that there is NO preload placed upon
the anti-roll bar. If there is any preload present, adjuster links will be difficult to turn by hand. If
necessary, adjust one of the link assemblies to a shorter length until preload is neutral. Do NOT add
preload to chassis using adjuster links.
Ride Height Full Extension Full Compression
30.Rotate each rod end body so that
it is centered within its clevis, then
tighten jam nuts.
31.Verify that all mounting hardware
is correctly installed and torqued
to specification.

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NOTES:

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NOTES:

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Chris Alston’s Chassisworks
8661 Younger Creek Drive
Sacramento, CA 95828
Phone: [phone]
Technical Support: [email protected]
915806-U10 REV 02/23/17
Chassisworks
Chassisworks
CHRIS ALSTON'S
CHRIS ALSTON'S
THE HOME OF HIGHER TECHNOLOGY
THE HOME OF HIGHER TECHNOLOGY
WARRANTY NOTICE:
There are NO WARRANTIES, either expressed or implied. Neither the seller nor manufacturer will be liable for any loss, damage
or injury, direct or indirect, arising from the use or inability to determine the appropriate use of any products. Before any attempt
at installation, all drawings and/or instruction sheets should be completely reviewed to determine the suitability of the product for
its intended use. In this connection, the user assumes all responsibility and risk. We reserve the right to change specification
without notice. Further, Chris Alston’s Chassisworks, Inc., makes NO GUARANTEE in reference to any specific class legality of any
component. ALL PRODUCTS ARE INTENDED FOR RACING AND OFF-ROAD USE AND MAY NOT BE LEGALLY USED ON THE
HIGHWAY. The products offered for sale are true race-car components and, in all cases, require some fabrication skill. NO PRODUCT
OR SERVICE IS DESIGNED OR INTENDED TO PREVENT INJURY OR DEATH.