Munching sway bar bushings like peanuts

i had the clunk/rattle going over bumps. had the sway bar bushings replaced and the noise was gone.

6-8 months later it was back and mechanic said bushings again. replaced again

2-3 months later guess whats back.

he told me that the links and struts were ok. he said the sway bar was
"worn" ( his words). not to doubt him but its a solid bar of metal. there are shiny spots where the bushings go, but it looks normal to me.

i know if i have them replaced again the noise going over bumps will be gone, but for even less time.

could the sway bar be worn?. or failing that what could cause it to munch through the bushings so fast?

most people i talk to say something in the front end

2002 ford windstar just past 81,000 km-----50340 miles

thx driving me nuts..

oh and i must say that place to download the owners manuals was sweet. thx a bunch for that one.

I have done the job 2 times ( sway bar bushing), with aftermarket bushing ( Moog). Depend of the year model it seem that different size of bar are installed and mine is 20.5 mm. So the 2 times I have ordered the bushing, the suppliers ask me about the size of the bar and he sold what it was supposed to go there. But the bushing just last a few months, and the clunking noise was back. The last time I have decided to order directly from Ford, and they just ask for the year model. When I have removed the aftermarket bushing, I have compared with the Ford's bushing and I can see that the diameter of the inside bushing was greater on the aftermarket bushing so I suspect that they were the wrong model size for my van. My new bushing doesn't show and wear so far ( no rattle noise) so I think that the problem was with the aftermarket model.

that clunk could also be the frame mount pulling free. Look at wiswind's signature line and he has pictures of the welding job to repair it. I chased that clunk/rattle/crunch around this spring and found it was the frame mount. I haven't done the job yet but know the problem now at least. Maybe Wiswind will chime in. As for the 2 sizes of bushings, I doubt you got the larger size one on by mistake. I looked at both the largar and smaller ones when new and the larger one is clearly "too large" if installed. I'd be looking at the sway bar end links to see how they are if you haven't already changed them it could be next.

Piper

On top of everything posted above, I believe the anti-sway bar on the Winny just "takes a beating" ... especially if rough or serpertine roads are involved. It's a front-end heavy vehicle. Even using the best OEM parts, we are going to have to keep an eye on the bar bushings and the links for adnormal wear. And any oil that escapes the engine or tranny will make the bushings wear out even faster.

The pictures were sent to me by another member with the request to post them.
They show his repair job....which he did himself.
I think I have a picture that shows them.....intact on my vehicle.
I had mine welded 2 times....the first time was $700 and lasted a year......the second time....different place...was $150 and lasted a long time.

the struts, the sway bar ends and links are all ok.

reason i ask is because when a new set is put on, the noise is gone totally and completely. until the new set get banged around by the roads.

the mechanic said everything was ok except the sway bar itself/ he said it was worn.

rob12345