Hellwig 7878 Rear Sway Bar for 2000-2005 Ford Excursion 4WD 4-6in Lift

Vehicle Fitment

• 2000-2005 Ford Excursion (4WD, 4"-6" Rear Lift, All Trims, All Engines)

Fitment Notes

• Fits 4WD configurations only - the lift-specific geometry of this bar is designed for the 4WD Excursion's rear axle and suspension mounting points.
• Requires 4"-6" of rear lift - this bar is specifically engineered for lifted applications and will NOT fit stock-height Ford Excursion models. For stock-height or lightly lifted Excursions, a different Hellwig bar is required.
• Fits all available engine configurations including the 5.4L V8 Triton, 6.8L V10 Triton, and 7.3L Power Stroke Diesel V8.
• Fits all Excursion trim levels (XL, XLT, Limited, Eddie Bauer) across all years of production (2000-2005).
• Installation may require drilling out factory U-bolt holes with a 9/16" bit to accommodate the larger-diameter Hellwig U-bolts - verify before installation.
• Includes 3-hole bar ends for rate adjustment and adjustable-length end links to fine-tune the installation for your specific lift height within the 4"-6" range.

Features

• Purpose-built rear sway bar engineered specifically for 4"-6" lifted 2000-2005 Ford Excursion 4WD - addresses the dramatically elevated center of gravity and increased body roll forces generated by the lift height on an already tall, heavy SUV platform.
• 1-1/4" (1.250 in. / 31.75 mm) diameter solid, heat-treated 4140 chromoly spring steel - a substantial upgrade from the factory bar, providing the roll stiffness needed to stabilize a heavily lifted Excursion during cornering, towing, and highway driving.
• 3-hole bar ends allow rate tuning to the driver's specific load and driving style - inner hole for maximum anti-roll stiffness, center for a balance of control and comfort, outer hole for a more compliant setting.
• Adjustable-length end links accommodate variation in actual lift height within the 4"-6" range, ensuring the bar can be leveled correctly for proper installation and performance regardless of which specific lift system is used.
• Reduces the pronounced rear body lean, cornering sway, and highway crosswind sensitivity that are amplified by the elevated center of gravity of a lifted Excursion.
• Direct bolt-on installation - no welding required. Minor drilling of U-bolt holes may be needed (9/16" bit).
• All components included in kit - no separate hardware purchase required.
• High-durometer polyurethane bushings for superior roll resistance, reduced noise and vibration, and long service life.
• Gray hammertone powdercoated finish for corrosion resistance in all weather and trail conditions.
• ISO 9001:2015 certified manufacturing at Hellwig's Visalia, California facility. Made in the USA. Backed by a Limited Lifetime Warranty.

Specifications

• Part Number: 7878
• Bar Diameter: 1-1/4" (1.250 in. / 31.75 mm)
• Bar Material: Solid, heat-treated 4140 chromoly spring steel
• Finish: Gray Hammertone Powdercoated
• Position: Rear
• Rate: 3-hole adjustable bar ends
• Drivetrain: 4WD only
• Lift Requirement: 4"-6" rear lift only
• End Links: Adjustable-length end links included
• Shipping Weight: 40 lbs.
• Shipping Dimensions: 40 in. L x 18 in. W x 6 in. H
• UPC: 745662078782
• Warranty: Limited Lifetime

Included Components

• 1x Hellwig 7878 Rear Sway Bar (1-1/4" diameter, chromoly, gray hammertone powdercoated)
• 1x Pair of adjustable-length end links
• 1x Set of high-durometer polyurethane bushings
• 1x Complete mounting hardware kit (including U-bolts)
• 1x Installation instruction sheet

Product Description

The Hellwig 7878 Rear Sway Bar is a lifted-application-specific rear suspension upgrade engineered exclusively for 2000-2005 Ford Excursion 4WD models running 4"-6" of rear lift. The Ford Excursion is one of the largest and heaviest body-on-frame SUVs ever produced in the American market, and when equipped with a lift kit in the 4"-6" range, its already elevated center of gravity rises further - dramatically amplifying rear body lean during cornering, loaded driving, and highway conditions. The factory rear sway bar geometry becomes incompatible with these lifted configurations, making a dedicated lift-specific bar essential for meaningful improvement in rear stability.

The 7878 solves this with a 1-1/4" solid heat-treated 4140 chromoly bar specifically engineered for the geometry of a 4"-6" lifted Excursion rear axle, including adjustable-length end links that accommodate variation within this lift range. The 3-hole bar ends allow rate tuning from maximum anti-roll stiffness for towing and loaded highway driving to a more compliant setting for improved ride quality. Installation is direct bolt-on without welding, though owners should be prepared to drill out the factory U-bolt holes with a 9/16" bit to accommodate the larger Hellwig U-bolts - a straightforward one-time step. All required hardware and polyurethane bushings are included.

This bar is engineered strictly for 4WD Excursions with 4"-6" of rear lift - it will not fit stock-height models or those with lift outside this range. All engine configurations are supported: 5.4L V8, 6.8L V10, and the 7.3L Power Stroke diesel. Built at Hellwig's ISO 9001:2015 certified Visalia, California facility and backed by a Limited Lifetime Warranty, the 7878 is a purpose-built American-made solution for one of the most aggressively lifted large-format SUV platforms in the aftermarket.