BEWARE | RD Sport Sway Bar Failure - BMW M5 Forum and M6 Forums
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post #1 of 21 Old 11th September 2016, 06:34 AM Thread Starter
umichchris
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BEWARE | RD Sport Sway Bar Failure

Yesterday afternoon on the way home from the office I did a simple lame change at roughly 30mph and heard a loud POP then metal scraping sounds...

My RD Sport front sway bar completely sheared through without warning.

This is a topic that's been brought up before, but I want to bring it to the forefront once more. Anyone running these should replace them immediately. I take my E60 up in the canyons, this could've happened at a VERY dangerous moment. Everyone please beware.







Swapped it out today for my OEM sways. Also, the damage was so violent that it bent my OEM end links...I'll have to replace those asap as well now.




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Last edited by umichchris; 11th September 2016 at 06:36 AM.
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post #2 of 21 Old 11th September 2016, 06:55 AM
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Sorry to hear Chris, is it in the same location as the others?

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post #3 of 21 Old 11th September 2016, 07:02 AM
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We found the bar was actually coming loose. I seem to remember you also had an unknown front end noise, IIRC?

Have any more pics of the clamps and bushings? That right one is way out of place, similar.





Sway Bar Warning 2 (Too)
As many of you know we have monitoring the sway bar and surrounding components carefully in the wake of the RD sway bars breaking on several members cars.

This is what we found in looking for an "unknown noise" .


The techs that originally installed the bar became short sighted in trying to quell the squeaking, that they forgot what matters, torq. spec. and some thread lock to keep the bolts from backing out.

The top bolt of the bar mounting clamp seats directly into the bracket welded on the sub-frame (no retaining nut).
We had to bend the clamp back into a "c position", bend the high pressure hose brackets back into place, regrease, remount the sway bar from end link to end link.


THANKFULLY the top bolt was sitting loose on top of the water platter when we removed it , or I would be SOL.


If ANYONE has serviced/replaced your sway bar or any related components, I highly recommend you keep a close eye on the mounts.






Last edited by Texasgrego; 9th July 2016 at 11:21 AM.
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post #4 of 21 Old 11th September 2016, 08:19 AM Thread Starter
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Quote:
Originally Posted by Texasgrego View Post
We found the bar was actually coming loose. I seem to remember you also had an unknown front end noise, IIRC?

Have any more pics of the clamps and bushings? That right one is way out of place, similar.





Sway Bar Warning 2 (Too)
As many of you know we have monitoring the sway bar and surrounding components carefully in the wake of the RD sway bars breaking on several members cars.

This is what we found in looking for an "unknown noise" .


The techs that originally installed the bar became short sighted in trying to quell the squeaking, that they forgot what matters, torq. spec. and some thread lock to keep the bolts from backing out.

The top bolt of the bar mounting clamp seats directly into the bracket welded on the sub-frame (no retaining nut).
We had to bend the clamp back into a "c position", bend the high pressure hose brackets back into place, regrease, remount the sway bar from end link to end link.


THANKFULLY the top bolt was sitting loose on top of the water platter when we removed it , or I would be SOL.


If ANYONE has serviced/replaced your sway bar or any related components, I highly recommend you keep a close eye on the mounts.






Last edited by Texasgrego; 9th July 2016 at 11:21 AM.


Nope, I did a front end refresh due to wheel wobble...no undiagnosed sounds. I put in new upper & lower control arms.


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post #5 of 21 Old 12th September 2016, 04:43 PM
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post #6 of 21 Old 12th September 2016, 08:16 PM
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This is what i was referring to, conversation from June 1st. I had a popping noise when we discovered what's above.

Did you shorten the end links when you installed the coilovers? If not, does this not cause tension between the new link position and the static bushing?
Remember Randy had to address this.

I have asked before, is there an instance of a bar breaking on a car that was not lowered?

Glad there was no serious damage


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Sh!t ive been tracking down a popping sound in my front suspension for the better part of 6mos....ive literally replaced everything:

- upper control arms w/ new bushings
- lower control arms w/ new bushings
- say bay end links
- installed coilovers

car handles like a dream but the sound is still there. I have RD sway bars....i wonder if i should take it off & inspect it...
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post #7 of 21 Old 12th September 2016, 08:23 PM Thread Starter
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oh ****, youre right, i do remember that now...but it turns out that the passenger side bolts were loose the brake caliper...once i tightened/torqued it back down the sound disappeared...


(also, that sound was present before lowering the car)

Quote:
Originally Posted by Texasgrego View Post
This is what i was referring to, conversation from June 1st. I had a popping noise when we discovered what's above.

Did you shorten the end links when you installed the coilovers? If not, does this not cause tension between the new link position and the static bushing?
Remember Randy had to address this.

I have asked before, is there an instance of a bar breaking on a car that was not lowered?

Glad there was no serious damage


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Sh!t ive been tracking down a popping sound in my front suspension for the better part of 6mos....ive literally replaced everything:

- upper control arms w/ new bushings
- lower control arms w/ new bushings
- say bay end links
- installed coilovers

car handles like a dream but the sound is still there. I have RD sway bars....i wonder if i should take it off & inspect it...

I do custom headlights & taillights
E46 ///M3 Vert - massive overhaul/rebuild project details here
E60 ///M5 Project #Patina
E36 ///M3 (sold) 5MT sedan

Last edited by umichchris; 12th September 2016 at 08:25 PM.
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post #8 of 21 Old 12th September 2016, 08:44 PM
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Damn.


So is this an inherent problem with the sway bar, or a bad batch of sway bars? Or is this caused by other factors putting unintended stresses on an otherwise good bar?
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post #9 of 21 Old 12th September 2016, 08:56 PM Thread Starter
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given the multiple reports of almost exact same type of failures here as well as the same type of failures report over on the M3 Forum for the E9x series platform...it seems like RD Sport simply made an inferior product. no way these things should be snapping like that.


the real messed up part is...my car handled 100x better with that bar on than it does now with the OEM bar. feels like a totally different car and not in a good way :/


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Originally Posted by Novabimmer View Post
Damn.


So is this an inherent problem with the sway bar, or a bad batch of sway bars? Or is this caused by other factors putting unintended stresses on an otherwise good bar?

I do custom headlights & taillights
E46 ///M3 Vert - massive overhaul/rebuild project details here
E60 ///M5 Project #Patina
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Last edited by umichchris; 12th September 2016 at 08:57 PM.
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post #10 of 21 Old 13th September 2016, 12:19 AM
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@umichchris sorry to hear about your failure. Do you know how many miles you had on your RDSways?

Quote:
Originally Posted by Novabimmer View Post
Damn.


So is this an inherent problem with the sway bar, or a bad batch of sway bars? Or is this caused by other factors putting unintended stresses on an otherwise good bar?
Quality Control went downhill -- not sure when.

I've been one of the lucky ones with my RDSways -- 53,000 miles of tracking and daily driving on my sways.

The failures are undeniable.

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