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Old 12-17-2015, 10:57 AM   #11
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Location: Spirit Lake, ID
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Clutchd, 34 years in structural and aerospace engineering, and many studies by NIST and ASTM have proven that harden bolts, (grade 8 and above) especially in applications where dynamic loading can apply, (i.e. moving items) and lock washers should not be applied. Yes you are correct that over tighten also leads to bolt failure. If loosening is a concern using self locking nuts, chemicals, (Loctite) or beveled washers would be the preferred method for providing additional holding power. In the late 1980's this topic came to light after several failures occurred in various industries and studies were performed on the root cause of failure modes. This is why the bolts that hold the sway bars have a wide head and serrated points that should provide enough holding power. Most likely the devices Ford used to tighten these were set incorrectly or an engineering error in the amount of torque needed was used.

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Old 12-17-2015, 11:24 AM   #12
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My 2012 FR 378XL had swage nuts and short bolts that came loose due to swage issue (probably over torque) which allowed the nut to back off/bolt to fall out/and subsequent bent sway bar holding bracket. This has been an issue for a long time with the Ford motorhome chassis. Thought it was solved but apparently not.

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