DIY Disconnects using oversized clevis pins. - Jeep Wrangler Forum
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Old 09-23-2007, 05:58 PM   #1
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DIY Disconnects using oversized clevis pins.

Just made some discos using clevis pins. Why go 7/16" and have it wobble all over the place when you can have a tight fit 1/2" pins with some force. Anyhow here is my detailed write up and "blueprints"
The clevis pins i bought were a bit long so i needed to cut them, if you can find some 2 3/8" clevis pins, it shouldn't need cutting.
I think the image speaks for it self.. the black washers are the stock washers that were used. Note the clevis pin is cut.



Stock Bolt removed.


The pins cut and ready to install.


It's pretty tight but with a hammer it goes in nicely.


Cannot stress more to note which way the clevis pin goes since taking it out takes a while to do. (Just in case you do have to take it out, use the stock screw to bang it out.)


Perfect length


Washer goes on and then the cotter pin goes in there.


When running disconnected simply remove the cotter pin, push the sway bar link towards the frame and then put the washer on and the cotter pin over for safe keeping.


I store mine like that but if you dont feel safe you can always tie them to the body.




Enjoy much better flexing and keep an eye on them for wear.

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Old 09-23-2007, 06:29 PM   #2
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Nice write up and nice pics. Defintily gonna "borrow" that idea from you.

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Old 09-23-2007, 06:45 PM   #3
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Thanks man and go ahead. Any questions feel free to ask me Don't forget pics too

The rusty hole.. At first it was hard to get the clevis pin in there since from all the rust so i needed to clean that up a bit.

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Old 09-23-2007, 07:10 PM   #4
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looks good!
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Old 09-23-2007, 07:24 PM   #5
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why didn´t you do it like all manufakturers of discos do it?
they all install the pins directly to the axle.

sorry, didn´t find a better pic.

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Old 09-23-2007, 07:26 PM   #6
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north east = rust. I live in the north east and have a 99 with 100,000miles and I have alot less rust.

nice job!!!
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Old 09-23-2007, 07:29 PM   #7
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Did this for Mine and Levs Jeep a few weeks back. Works pretty good.

Nice write-up trip.
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Old 09-23-2007, 08:00 PM   #8
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Quote:
Originally Posted by nicolas-eric View Post
why didn´t you do it like all manufacturers of discos do it?
they all install the pins directly to the axle.
because the hole in the stock link is a little smaller than 1/2 but they are cut like this (with the slit) Thats why the 1/2" clevis pins need to be hammered inside. It not hammering them hard but you still need a hammer.

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Old 09-23-2007, 08:39 PM   #9
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Quote:
Originally Posted by nicolas-eric View Post
why didn´t you do it like all manufakturers of discos do it?
they all install the pins directly to the axle.

sorry, didn´t find a better pic.
Ditto. I picked up some hitch pins from Tractor Supply after wearing out my first set of clevis pins.
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Old 09-23-2007, 08:45 PM   #10
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Joel.. like those? They can work also as longs as the hole for the cotter pin is 2 1/4" away from the other side.


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