Hellwig 7640 Big Wig Front Sway Bar for 1999-2004 Ford F250/F350 Super Duty 4WD

Vehicle Fitment

• 1999-2004 Ford F-250 Super Duty (All Trims, 4WD, Stock Height to 6" Lift, All Engines)
• 1999-2004 Ford F-350 Super Duty (All Trims, 4WD, Stock Height to 6" Lift, All Engines)
• 2000-2005 Ford Excursion (All Trims, 4WD, Stock Height to 6" Lift, All Engines)
• 2000-2007 Ford F-450 Super Duty Cab & Chassis (2WD)
• 2000-2007 Ford F-550 Super Duty Cab & Chassis (2WD)

Fitment Notes

• F-250, F-350, and Excursion fitment is for 4WD configurations only - does not fit 2WD pickup variants of these models.
• F-450 and F-550 fitment is for Cab & Chassis body style, 2WD only.
• Compatible with stock ride height through 6" of front lift on F-250, F-350, and Excursion 4WD applications.
• This bar reuses the factory front end links - end links are not included in the kit and must be retained from the original vehicle.
• Designed for use with the factory exhaust system; aftermarket exhaust configurations should be verified prior to installation.
• CARB compliant - CARB E.O. Number on file; legal for use in California.

Features

• Big Wig heavy-duty front sway bar - engineered specifically for the 1999-2007 Ford Super Duty and Excursion platform with a larger-than-stock diameter for dramatically improved roll stiffness.
• 1-1/2" diameter solid, heat-treated 4140 chromoly spring steel - significantly larger than the factory bar for a major improvement in front-end lateral stability.
• Reduces front body roll and understeer during cornering, keeping weight more evenly distributed across all four tires for improved traction and driver confidence.
• Compatible with suspension lifts up to 6", making it an ideal upgrade for both stock-height and lifted Super Duty and Excursion builds.
• Reuses factory end links for a clean, OEM-integrated installation with no aftermarket link hardware required.
• High-durometer polyurethane bushings included for superior roll resistance, reduced noise and vibration, and longer service life versus rubber.
• Gray hammertone powdercoated finish for long-term corrosion resistance across all operating and weather conditions.
• Heat-formed as a single piece from 4140 chromoly steel - more structurally consistent at the bends versus cold-bent alternatives.
• Quick bolt-on installation using factory mounting locations - all mounting hardware included.
• ISO 9001:2015 certified manufacturing at Hellwig's Visalia, California facility. Made in the USA. Backed by a Limited Lifetime Warranty.

Specifications

• Part Number: 7640
• Bar Diameter: 1-1/2" (1.500 in.)
• Bar Material: Solid, heat-treated 4140 chromoly spring steel
• Finish: Gray Hammertone Powdercoated
• Position: Front
• Rate Type: Fixed
• Lift Compatibility: Stock height to 6" lift (F-250/F-350/Excursion 4WD)
• End Links: Reuses factory end links (not included)
• UPC: 745662076405
• Warranty: Limited Lifetime

Included Components

• 1x Hellwig 7640 Big Wig Front Sway Bar (1-1/2" diameter, chromoly, gray hammertone powdercoated)
• 1x Set of high-durometer polyurethane bushings
• 1x Complete mounting hardware kit
• 1x Installation instruction sheet

Product Description

The Hellwig 7640 Big Wig Front Sway Bar is a direct-fit handling upgrade engineered for the 1999-2004 Ford F-250 and F-350 Super Duty (4WD), 2000-2005 Ford Excursion (4WD), and 2000-2007 Ford F-450 and F-550 Cab & Chassis (2WD). The factory front sway bar on these platforms is sized for general-purpose use and falls short when the vehicle is used for heavy towing, hauling, or lifted builds where front body roll becomes more pronounced. The Hellwig 7640 replaces the factory bar with a solid 1-1/2" heat-treated 4140 chromoly bar - a significant step up in diameter that delivers major improvements in lateral stiffness, cornering response, and front-end stability. The result is a truck or SUV that stays far more level in turns, tracks more predictably during load-influenced cornering, and feels substantially more controlled at highway speeds.

One of the most practical advantages of the 7640 is its compatibility with suspension lifts up to 6" on the F-250, F-350, and Excursion 4WD applications - making it a strong choice not just for stock-height daily drivers and tow rigs, but also for lifted builds where the factory sway bar geometry becomes less effective. The bar is engineered to retain the vehicle's factory front end links, simplifying installation and maintaining a clean, OEM-integrated look. High-durometer polyurethane bushings are included and provide superior roll resistance and reduced deflection compared to standard rubber bushings, with all mounting hardware needed for installation included in the kit.

Fitment spans the complete 1999-2004 Ford F-250 and F-350 Super Duty 4WD lineup, the 2000-2005 Ford Excursion 4WD, and the 2000-2007 Ford F-450 and F-550 Super Duty Cab & Chassis in 2WD configuration, covering all trim levels and engine options across these platforms. This bar is CARB compliant and legal for use in California. Built at Hellwig's ISO 9001:2015 certified Visalia, California facility and backed by a Limited Lifetime Warranty, the 7640 is a proven American-made upgrade for one of the most capable and heavily used Super Duty generations ever produced.