All,
I removed the sway bar links with the intent of replacing the rubber U/L rubber bushings. They are over 35 years old.
I did not remove the interior clamps that hold the bar to the body. Too difficult to access the bolt heads and nuts.

Problem: When I went to try to connect the sway bar to the upper and lower link connection points the bar is too far apart for the nuts to connect to the bolts.
What am I doing wrong with what I thought should be a pretty simple job?
Thx

 

I'm not clear on what "U/L" bushings are.

If I understand correctly you can't get the nuts started on the end links; as if the end kinks were too short. Do I have that right?

If so, I fight that problem all the time on various cars.

Sometimes replacement end link bushings are just to thick and take up too much space, so to speak. I've sometimes trimmed each bushing bit.

If the car is elevated with the suspension hanging then try doing-up the end links with the weight of the car on the suspension.

Cheers
DD

 

If the suspension is hanging, it will be tough. I have done the with the vehicle on the ground without much issue.

 

Thanks,
I have tried it both ways. I'll try again today with it on the ground

 

I just had the same issue with my XJ6. It seemed like the link rubbers were too thick and I could not get the top nut attached. I then placed the jack under the lower control arm and lifted the arm. My helper (good to have one in this case) used a pry bar and he pushed down on the sway bar and we were able to attach the top nut. After which we tightened the bottom and top nuts a little at a time. Hope this helps.