Sway Bar Link Issues - Off-Road Forums & Discussion Groups

Rubi04Jeep · #1 10-12-2009, 02:13 PM

I am trying to replace the stock sway bar links on a 04 Wrangler. My passenger side link was significantly deteriorated and appears to have broken in two parts. I was able to remove the majority of the old link, but what is left seems to be the top part. I've attached what is left of the old link as well as a side by side comparison of what I was able to remove vs what the new link looks like. The top image is what is left, and the bottom image is the comparison.

I think I am fine to remove the top part of the link by force

I just wanted to make sure that I was not going to damage something that I was going to need. I think the new link is fine, I don't see how I need that top part anything, but just have to ask.

Any help is greatly appreciated. I did not have the funding to replace them with disconnects, and opted for the straight stock replacement.

I did try searching, and read a few write-ups on various sites, most of them focused on the installation of disconnects which I the process is similar if not the same. The driver side is not as deteriorated, and will be done next. Am I right to assume that removing the link will be the same, but, when I go to tighten the link I will need to lift up the front end to add some pressure so it tightens properly?

Jim_Lou · #2 10-12-2009, 02:26 PM

Welcome to the board!

Brute force will be fine, or grinder or Sawzall or heat or hot wrench. Don't apply heat to the sway bar itself, though. As for aligning the bar to connect the new links, do whatever it takes. You should be able to just push the bar up and down enough by hand, but if it fights you, slip a pipe over the other end and have a buddy maneuver it as necessary.

Rubi04Jeep · #3 10-12-2009, 05:28 PM

Thank you, that worked great. The second link came off without a problem from the lower connection but had the same issue connecting to the sway bar itself. A few hits with the large face hammer and a glorious ping sound was heard

The problem I am having now has more to do with the fact that I spent a number of years in new england first. All of the associated hardware (and a lot of the front end for that matter) needs some attention. There is some rust on the bolt ends as well as the top nut/washer combo. Should I just wire-brush it and apply some wd-40? Is there a good spray paint to coat it lightly with to prevent this in the future?

Jim_Lou · #4 10-12-2009, 07:12 PM

NOT WD40! In relatively short time it will evaporate and provide no protection. Since you suggested WD40 I'm guessing that you aren't real particular about appearance. I suggest wire brushing, wiping down with paint thinner and then using a 1" brush to apply Rustoleum Satin Black. It's a whole lot cheaper than the same product in a spray can, makes much less mess and will provide good protection for a long time.

A couple of tips - Harbor Freight has boxes of 1" wide natural bristle chip brushes. I don't remember the price or number in the box, but IIRC it works out to about a quarter per. Not worth the amount of paint thinner it takes to clean one. Store the can of paint upside down. It's much more effective at preserving the paint in the can, and makes it easier to stir before use.

Rubi04Jeep · #5 10-12-2009, 10:44 PM

Thanks for the heads up Jim. I am not too particular on appearances, but I just threw wd40 out there as something for general protection. I like the idea of painting the parts, I just wasn't sure if I should be using any other type of lube around the bushings.

Jim_Lou · #6 10-14-2009, 05:25 PM

Actually, rubber bushings shouldn't be lubricated. They're meant to flex. If they're lubricated and slide they'll wear faster. On the other hand it's good to keep the exposed surfaces protected with Armorall or a similar concoction.