Rear Sway Bar Removal and Installation

Overview

This procedure outlines how to remove and install the rear sway bar on a Porsche 944 with a 16v engine. The rear sway bar helps stabilize the vehicle during cornering, and this maintenance may be needed to replace a worn sway bar, upgrade to a performance version, or access other suspension components. The process is straightforward and can be completed with basic tools, making it accessible for DIY enthusiasts with mechanical experience.

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Tools Required

• Metric socket set (including 13mm (1/2 inch) and 17mm (11/16 inch) sockets)
• Metric wrench set (including 13mm (1/2 inch) and 17mm (11/16 inch) wrenches)
• Floor jack
• Jack stands (pair)
• Torque wrench (capable of 25 Nm (18 ft-lbs) and 46 Nm (34 ft-lbs))

Parts Required

• Rear sway bar (if replacing, 944 333 031 00)
• Sway bar drop link bolts (4, 900 067 103 02)
• Sway bar mounting bolts (4, 900 067 104 03)

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Park the vehicle on a flat surface and engage the parking brake.
2. Use a floor jack to raise the rear of the Porsche 944, lifting at the designated rear jacking points near the torque tube.
3. Secure the vehicle on jack stands placed under the rear chassis rails, ensuring the vehicle is stable and level.
4. (Optional) Remove the rear wheels using a 19mm (3/4 inch) socket to improve access to the sway bar. This step is not mandatory but makes the job easier.

Step 2: Disconnect the Sway Bar from the Drop Links

5. Locate the sway bar drop links on both sides of the rear suspension. These connect the sway bar ends to the control arms.
6. Using a 17mm (11/16 inch) socket and wrench, remove the bolt and nut securing each drop link to the sway bar (two bolts total, one per side). Hold the nut with the wrench while turning the bolt with the socket to prevent spinning.
7. Retain the bolts and nuts for reinstallation or replace them with new ones (900 067 103 02) if damaged.

Step 3: Remove the Sway Bar

8. Locate the sway bar mounting brackets, which secure the sway bar to the torque tube carrier (the central housing under the vehicle).
9. Using a 13mm (1/2 inch) socket, remove the four bolts (two per side) that attach the sway bar brackets to the torque tube carrier.
10. Carefully slide the sway bar out from under the vehicle, ensuring it clears the torque tube and exhaust components.

Step 4: Install the New or Reconditioned Sway Bar

11. Position the new or reconditioned sway bar (944 333 031 00) in place, aligning it with the mounting brackets on the torque tube carrier.
12. Secure the sway bar brackets to the torque tube carrier using the four 13mm (1/2 inch) bolts (900 067 104 03). Tighten the bolts to 25 Nm (18 ft-lbs) using a torque wrench.
13. Reattach the sway bar to the drop links on both sides using the 17mm (11/16 inch) bolts and nuts (900 067 103 02). Tighten to 46 Nm (34 ft-lbs).

Step 5: Finalize Installation

14. If the rear wheels were removed, reinstall them using a 19mm (3/4 inch) socket and tighten the lug nuts to 130 Nm (96 ft-lbs).
15. Lower the vehicle by raising it slightly with the floor jack, removing the jack stands, and gently lowering it to the ground.

Post Procedure Checklist

• Verify that all bolts (drop link and mounting brackets) are tightened to the specified torque values (25 Nm (18 ft-lbs) for brackets, 46 Nm (34 ft-lbs) for drop links).
• Inspect the sway bar and drop links for proper alignment and clearance from other components, such as the exhaust and torque tube.
• Test drive the vehicle for 5 miles (8 km) at low speeds, checking for unusual noises or handling issues that could indicate improper installation.
• After the test drive, recheck the torque on all bolts to ensure they remain secure.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube