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Old 03-04-2013, 11:54 PM   #1
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DIY $10 Quick Disconnects

I made a comment about DIY Quick Disconnects on another thread, and my PM has been blowing up since. So here is a quick write up for DIY Quick Disconnects for JKs and TJs:

(YJ guys, you get love too. Simply replace the bottom nut on your links with a wingnut and lock washer.)

I only recommend using these as a temporary fix; I only use this to/from the trails and otherwise use the stock hardware. There will be a little motion out of the sway bar in this setup, as the clevis cannot hold the link snugly to the mount. This will cause a clunking sound on bumps and will wear down the clevis pin over time, which is why I recommend only temporary usage of this setup. I AM NOT RESPONSIBLE IF SOMETHING SHOULD FAIL.

JK QUICK DISCOS

JK-1: Replace this bolt (18mm) with a Grade 8, 1/2in diameter 3in length Clevis Pin, a couple of 1/2in Grade 8 Washers, and a Cotter pin. (There are multiple ways to accomplish this, this is the way I chose, get creative and use what you can find. Just make sure that it's safe.)

JK-2: To disconnect remove clevis pin and rotate the sway bar link so that it rests directly on top or under the sway bar and secure it to the sway bar with a zip strip or something. I actually like to use electrical tape for this purpose.

When re-connecting park on level ground, and start with the passenger side first.

SAFETY CONSIDERATIONS

*It's best to leave the sway bar horizontal to the ground so that the tires clear it normally. There is usually enough tension on the bar so that it doesn't move. If you need to you can rotate the sway bar up and out of the way. Turn your wheels full lock to ensure that you do not rub.

**I only use the clevis pins when I am on my way to and from the trails. I still use the stock bolts when I am doing my daily driving, I just change them out the night before I hit the trails. It's easy enough to change them and I think this way will be the safest way to use any quick discos.

***It is important that you use GRADE 8 hardware. This will mitigate possible failure that could result in an accident.

****Secure your hardware when you remove anything, don't put it on your fender and drive away.

MOST IMPORTANTLY: It is generally unsafe and not a good idea to operate at speeds above 20MPH with the sway bars disconnected.

TJ QUICK DISCOS

I don't have a TJ, but the concept is similar. I've seen two different types of sway bar links so I've included something for both. If you DO have a TJ, and make your own discos, post it up here with pics so your fellow TJ owners have a better reference.

TJ-1: Replace this bolt with a Grade 8 Clevis Pin, a couple of Grade 8 Washers, and a Cotter pin. (I don't know the measurements so you are going to have to remove it first, and then get the measurements. There are multiple ways to accomplish this, get creative and use what you can find. Just make sure that it's safe.)

TJ-2: Replace the top nut with a wing nut and lock washer which will allow you to remove the entire sway bar link when you want to disconnect. (With this kind of sway bar link you cannot rotate it out of the way when you remove the clevis pin, so you will have to remove and secure the entire link.)

TJ-3: If you have this kind of sway bar link, when you disconnect just rotate the link up to the sway bar and secure it with a zip strip or my favorite, electrical tape.

When re-connecting park on level ground, and start with the passenger side first.

SAFETY CONSIDERATIONS (In case you skipped the JK section)

*Figure out a good place to secure your sway bar so that the tires clear it naturally. Turn your wheels full lock to ensure that you do not rub.

**I only use the clevis pins when I am on my way to and from the trails. I still use the stock bolts when I am doing my daily driving, I just change them out the night before I hit the trails. It's easy enough to change them and I think this way will be the safest way to use any quick discos.

***It is important that you use GRADE 8 hardware. This will mitigate possible failure that could result in an accident.

****Secure your hardware when you remove anything, don't put it on your fender and drive away.

MOST IMPORTANTLY: It is generally unsafe and not a good idea to operate at speeds above 20MPH with the sway bars disconnected.

(Disclaimer: I did not come up with this on my own; it is a compilation of different threads, forums, articles, and some of my own ideas. I have re-purposed images from elsewhere on the internet to better demonstrate. The actual cost will obviously vary, I spent roughly $8 on mine.)
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Old 03-05-2013, 10:27 AM   #2
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Now that it's daylight, here are a few pics of my actual setup on my JK:
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