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post #1 of (permalink) Old 03-30-2001, 10:33 AM
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Making Sway bar Quick disconnect

I'm looking for unique ideas for a quick disconnect for YJ sway bars. I'd rather not dump $90 when I know there is a better way, wether it be a new bracket or modifying the sway bars. I thought about removing them but it's a daily driver. Any input on removal would be helpful. Even extreme ideas will be considered!

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post #2 of (permalink) Old 03-30-2001, 01:19 PM
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Re: Making Sway bar Quick disconnect

Well here's what I did. I cut the factory link in half. Well actually not in half. There is a (almost! [img]/wwwthreads_images/icons/mad.gif[/img]) straight section in the middle. I divided and marked this into 3 equal sections and cut it so one half has one third and the other half has two third left. The rod is about 1/2 inch so I went and got a 1/2 inch threaded coupler. It's about 1.5" long and has a hex cross section. They come in all sizes. I got mine in Lowes. I also got a 1/2" thread die and a handle. I threaded both and of the two halves, one for 1/3, the other for 2/3. The coupler can thread over the shorter piece, locking it firmly together. To disconnect, just unscrew it so the coupler goes over the longer rod and stays there. Then you can fold the two halves out of the way. You can screw/unscrew it with bare hands, no wrench needed! It actually adresses the problems that ALL other commercial sway bar discos have: hard to put them back on! You have to twist the sway bar to allow the rod to slide into the tube about an inch and then try to line up the holes to put the pin in. The only issue with this setup that you have to cut the thread which is a b!tch! The rod is sometimes slightly larger than 1/2" and has a slight bend in it so you have to trim it first. I used a grinder and a file as I went on with the threading. You'll see the thread going out to one side when it reaches a slight bend. Anyway you can trim it enough and cut enough thread to take almost all the coupler screwed on. Mine ended up about 1/8 short but still works. Btw, you only have to do one side and leave the other connected. It'll work fine. Total cost is $11. I stop now cuz my arms hurt from all the threading. [img]/wwwthreads_images/icons/smile.gif[/img] Later.

'91 YJ,I-6,2.5" lift,Boomerangs,33s,D30,D35c,Lock-Rights F&R
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post #3 of (permalink) Old 03-30-2001, 01:47 PM
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Re: Making Sway bar Quick disconnect

Chuck the sway bars. I havent had the ones on my rig for almost two years and have no problems. Its not driven daily but I probably put about 200 miles on it a week anyway. I also chucked the track bars. You just have to remember that you are not driving a sports car. And the cost...FREE, have fun.

Kris

I do the same thing every weekend, its just the location where I do it that changes!
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post #4 of (permalink) Old 03-30-2001, 03:10 PM
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Re: Making Sway bar Quick disconnect

Here are the directions that I found on the web for making discos on my CJ:

[quote]Cheap and Easy Sway Bar Disconnects for CJs and YJs
The idea of the Minute Mods series is to bring you projects that are quick, easy or dirt-cheap. This month's Minute Mod is all three.
The first modification done to any trail vehicle should be installation of solid tow points if it doesn't already have them. The second should be to disconnect the sway bar for better trail performance.
There is a very simple and easy way to make your own sway bar disconnects for a CJ or YJ. You will need a grinder or hacksaw, a hand drill, a 1/4" drill bit, and a 5/16-18 tap. For materials you will need only two 3/4" long 5/16-18 bolts, two lock washers, and two fender washers. Many CJ and YJ owners already have the correct tap since it is the same tap used when installing an aluminum valve cover on an '81 or newer 258.
The sway bar was removed from the YJ to make it easier to shoot the pictures for this article. I have also done this project with the sway bar still installed on the vehicle and found it no more difficult. Removing the front tires gives all the room needed to complete this project while the sway bar is still on the Jeep.
The first step is to remove the large washer that is the head of the link pin that goes into the sway bar. I've found that grinding the washer with an angle grinder is the quickest and easiest method of removing it. You could also use a hacksaw or Sawzall type saw. Try to remove only the washer and leave the link pin as long as possible. When grinding, grind only until you see a crack all the way around where the washer and shaft of the link pin meet and then pry the remnants of the washer off. You will want to cut as close to the head as possible when using a hacksaw or Sawzall. The link pin material is fairly hard, so start with a new blade and be patient.
You can remove the nut and washer that secure the lower end of the sway bar link to the spring plate if the sway bar is still installed on the vehicle. The Link should slide off fairly easily now.
Remove the sway bar link and make sure that the end of the bolt is squared and flat. Grinding a small chamfer on the end of the link pin body at this time will make installing the links easier later. Center punch the body of the body of the link pin, drill and tap it. I have used a hand drill while the sway bar was still on the vehicle with great success on other Jeeps. A drill press was used for these pictures but it is not necessary. Don't worry if the hole comes out slightly off-center. It will still be functional as long as you don't drill through the side of the link pin body or make the hole at a large angle.
Once the hole is tapped the link can be replaced and secured to the link pin with the bolt and washers. The nut and washer on the spring plate should be re-attached as well. The small bolt and washers will hold the link on with no problems because there is no side force on the link. [\quote]


I drilled my pins on the Jeep but those pins are hard, I would recomend that you take them off and use a drill press.

Karl
80 CJ/YJ-7 FrankenJeep
94 Grand Cherokee
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post #5 of (permalink) Old 03-30-2001, 03:17 PM
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Re: Making Sway bar Quick disconnect

Man, you gotta tell me what you used to drill the pins. I tried that same route first, wanting to drill both the pin and the stud on the spring plate. The spring plate stud was no problem but that pin got me! After ruining the 3rd drill bit I gave up and went for another solution.

'91 YJ,I-6,2.5" lift,Boomerangs,33s,D30,D35c,Lock-Rights F&R
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post #6 of (permalink) Old 03-30-2001, 03:18 PM
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Re: Making Sway bar Quick disconnect

Can you post the link to this article? I'd like to see the pictures.

'91 YJ,I-6,2.5" lift,Boomerangs,33s,D30,D35c,Lock-Rights F&R
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post #7 of (permalink) Old 03-30-2001, 10:46 PM
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Re: Making Sway bar Quick disconnect

I made discos for my CJ7.
1. I removed the factory links from the jeep.
2. CJ links are straight.
3. I cut the links in half.
4. I purchased a 1/2" galvanized pipe the length of the original link.
5. I cut the threaded portion off the ends of the pipe.
6. I ground the link down so that it would fit inside the pipe.
7. I inserted both ends of the original link into the pipe.
8. Now the link looks like before I cut it, but with a pipe around the mid-section.
9. Drill holes through the pipe and the link on both ends about an inch away from the round head.
10. Insert removeable pins like on the $90 discos.
11. You are done....


Later,
Cost less than $10...

http://home.off-road.com/~tom85cj7/home.htm
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post #8 of (permalink) Old 03-31-2001, 01:19 AM
 
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Re: Making Sway bar Quick disconnect

Somebody did it on jeepin.com
Check the tech section

1976 CJ5
SWB BBS Member Page!(exclamation)
http://www.shortwheelbase.com
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post #9 of (permalink) Old 03-31-2001, 11:03 AM
 
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Re: Making Sway bar Quick disconnect

Here's my CJ5 disco's
Very easy and got everything from the hardware store.
My disconect

A simple drawng of the disconect


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post #10 of (permalink) Old 03-31-2001, 02:10 PM
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Re: Making Sway bar Quick disconnect

Give Slick Rock a call at (972) 221-8859 they make a set that replace the stud on the sway bar. I bought a set 4 years ago and they were $36.00 shipping included.

http://www.geocities.com/yj-wrangler/bar1.jpg
http://www.geocities.com/yj-wrangler/bar2.jpg
http://www.geocities.com/yj-wrangler/bar2.jpg


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