Well, I was doing a project on my C4 LT4, installing a hurst short throw shifter, which went really well believe it or not (took longer than it should have, but went well), and while I had the back half of the exhaust out (I had cut it and added v-bands to make it easier to remove, and at that time got rid of the resonator seeking a throaty rumble), I decided to take off a few parts and have them powder coated. I did this on my C6 GS, and liked it, so thot I’d do it to the C4. So, I did that and the powder coating turned out great (see pic). I did the sway bars (stabilizer bars as the FSM calls them, the end links, and the Vansteel camber brace. I go to install it and no problems on putting the rear bar in, but man, the front has been a bitch. Kinda reminds me of the #8 spark plug. Why does almost everything I do on this car take like 6-8 times longer than it should? Sway bar install should take maybe an hour, perhaps 2 at most if you remove the wheels. And I have a lift so that makes it a bit easier and faster but not with this front bar. I finally got it in, but one bolt on the driver side bracket simply will not go back in. I’ve tried multiple times, cleaned the threads on both the hole and the screw, ensured it was lined up, etc. That said, I guess I somehow cross threaded it. I am not real familiar with tap and dye tools but I do have a little kit so guess I will try that this weekend. I’m going pick up a new screw as well. Three of the 4 screws are in so it’s secure and not going to come loose, but it really bugs me. I’ve never had this much trouble with a sway bar.

I’m all ears for any suggestions from my esteemed C4 colleagues.

Even located new rubber bushings for the sway bars and end links. And the powder coating place even had a press and removed the old and installed the new post powder coating.

My C6 GS is so much easier to work on than this C4 is…..I am pretty angry with my C4 at the moment. Literally everything (except fluid changes) takes so much longer to do than it should. I’ll like her again, but I’m super pissed at her right now…..


Rear sway bar and links already in; pictured is the front bar, frond end links, brackets, and the camber brace.


Parts at powder coating pick up, camber brace is wrapped in the towel.


(Pictures are not showing on the post, but they are when I go to edit….not sure what’s up with that.)

 

Sorry to hear the sway bar install was a bitch of a job, with experience comes knowledge. All I can say is buy a common size tap and die set, you will always need to chase a thread and clean it in future. Is a worthwhile investment, you will always need it.
One more tip, if you think a sway bar is difficult don't even consider a heater core replacement, now that is enough to drive anyone to drink. They say GM engineers started with a heater core and built the car around it ....

Just be glad you don't have a modern japanese car, there is no room for that endangered 10mm socket to even fit. If your 5 year old with arms small enough that could fit in to get to the fasteners

 

Appreciate the tip; you are correct, experience breeds knowledge for sure. Yeah, I don’t plan on doing a heater core replacement, I’ve read others experiences already so hope that doesn’t need to happen on my car, and least not for a good while (only have 24k miles on the car). I’m at decent level of ability, above average I’d say, but I guess since I cross threaded that one bolt, it just ruined the entire process. Still can’t believe the thing game me that much trouble. I literally just completed the short throw shifter install, and while it was decently involved, it all went as it should without problems, just took some time. Then I do something simple and it gives me fits. Anywho…. I’ll redo the threads, put a new bolt in there and be good to go….will just take more time….

Owned one about a decade ago, but no chance I’ll ever purchase another Japanese vehicle, but thanks for the heads up on that one too.

 

When I was replacing the gears in my headlights, I cross-threaded one bolt. I was pizzed at myself for being sloppy (it was late and I was tired) but I powered it down and it seated firmly. The headlights work fine and even though I think about it from time to time (being as OCD as I am), I figure it'll never come out again so let it go. But I hear ya...nothing on these cars is easy and everything is packed in like sardines. Patience...which I have little of...is the key.

Always enjoy your threads

 

Thanks Rogue One, appreciate it. Yeah, I'm pretty thin on patience too, but getting a little better in that regard as I age however. That said, I definitely ran out of patience on this front sway bar install.

 

I'd venture that the powder coating closed up what were slightly oversized holes in the bracket and ruined the alignment.
Cure: take a rat-tail file and open up both holes on that side of the bracket, removing the coating in the holes.
If it came out it will go back in.

 

Good point Rocco, I will check that out; thanks for the suggestion. That could very well be a contributing factor. I have it on my agenda to address it this weekend and that'll be one item I include on my fix list. I'm running by the store today on my way home from work and picking up a couple new bolts. Already have a tap and dye kit, so am planning to file the bracket holes a little bit, re-tap/clean the receiving hole threads, and use the new bolt.....hopefully, that'll solve it.

 

Well, I’m pleased to note that I was able to re-tap that front sway bar bracket hole, insert a new bolt, and it all went well and she’s all buttoned up. Got the newly powder coated Vansteel camber brace installed too, was super careful, taped it up, and actually didn’t scratch it putting it in either! The goal was to accent the LT4’s red color of the intake. Hopefully the pics will show up this time.


View of front sway bar and end links.

From passenger side.

From driver side.

From top.

Rear sway bar. Forgot to take a pic after installing the mufflers. With mufflers in, it basically hides almost all of the bar, but still did it anyway.

Rear view without mufflers or spare tire and carrier.

 

Looks great.

 

Thanks!