In Reply to: Here we go again..... posted by Mark S. on August 04, 2000 at 11:07:25:
Here's the sure-cure fix *unless* you have a bad endlink. Otherwise the endlink must be replaced, with which it will never come off again using this procedure.
Clean off bar end and hole in endlink with a strong grease-cutting solvent, taking the necessary flammability precautions. Be sure and get it extra clean, absolutely no oil or grease must be present! Spray a small amount of regular WD40 (don't use anything else, especially if it specifies graphite, teflon, etc) on bar end and endlink hole, then press bar end into endlink. It should be a very tight fit and require a lot of effort, but it will go on. Allow WD40 to dissipate for about 30 minutes before moving anything; it will dry out and create a bond between the rubber endlink mount and the bar end that is unusually strong.
Just to give you an idea how strong the bond is we once used WD40 to seat a race tire on a rim after repeated pressurizations to 100 psi would not pop the tire bead onto the rim seat. When we went to remove the tire after it was worn out we worked on trying to break the tire off the bead seat for almost 45 minutes with the tire machine plow before they would separate; I almost thought I was going to have to hand cut the tire off the rim with a hacksaw before it finally popped the bond.
For the record, I had the lefthand endlink pop off once, and only once. I check it often and it has never budged since. I suspect the initial issue is a factory installation deal, with people using grease or oil related products to reseat it later, which will surely result in popping it off again in very little time. I installed a larger rear swaybar on my previous E36 M3 for testing purposes and I had one hell of a time removing the endlinks from the original bar. This method of attachment is very good; it's been in use many years on various BMW models, but only if the right type of installation is performed.