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Old 05-15-2011, 10:35 PM   #1
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Guide: How to build Home Made Sway Bar Quick Disconnects

Well, sadly I didnt take any pictures during the actually fabrication of the Discos, but I will give detailed directions on how to do everything, along with pictures of parts, how its used and done, etc.

To start with you need parts.

Parts:
2 2' 1/2 7/16cotter pins
2 small diameter lynch pins, slightly too large to fit holes in cotter
4 7/16 washers (plus two more if you dont have your originals with your sway bar for whatever reason)

Tools: Drill, drill bit set, rubber hammer, pliers, T55 Torx bit and wrench sets.

Alright so that should have us covered.

First, you need to remove your original bolts from both sides of the sway bars. Youll use your T55 and a wrench, and tada. next, you check and make sure you bought the right parts, and you have enough washers to fit tightly on around the sway bar and cotter/lynch. Put the cotter pin through the hole, and put your three washers in with it. One against the head of the cotter pin, one on the inside of the sway bar on the cotter pin head side, and one on the outside opposite. You should be able to press them tightly and look at which hole on the cotter pin lines up with a tight fit. for me it was the next to last. depending on brand of parts this could vary. you may find you need to adapt number or thickness of washers to make a tight fit.

After determining which hole will line up, you need to select a drill bit just slighly larger than the hole in your cotter pin. hold the cotter pin with your hand, or a vice grip/pliers if you must. carefilly drill straight down through the hole, making it larger. Make sure your lynch pin fits through without catching, and isnt too tight that it will be a pain to put in or out, but isnt too lose than it will shift and be able to break. it should fit snuggly. drill out both cotter pins.

Then go back to your jeep, reassemble like you did earlier, and slide your lynch pins through and close them. check to see that they all fit tight. you may find you need a rubber hammer, or to push with your foot on the body/frame to shift one side of the sway bar into alignment if you have done one side already, and you are on unlevel ground. a rubber hammer can be used to assist in aligning the disconnects. you may want to carry one in your jeep incase this happens on the trail. if all else fails, remove one washer and then replace it at home before any highway driving.

But there you have it. quick disconnects for around $7. you may want to purchase an addition cotter pin and linch pin, and drill out the cotter pin, to carry with you incase one breaks. Check the parts from time to time for any breaks or wear on the parts. Grade 8 of everything is suggested if you can get it, but grade 5 will do, especially if put together right. These may not be ass efficent and clean as JKS or others, but for us do it yourselfers, it gets the job done.

Any questions or what so , let me know.











Before:

After:

I know the change in flex is minimal, but its a 8 inch rock. your not gona get much flex either way. ill try to get to some bigger stuff or trails this week for better pics. Enjoy!

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Old 05-29-2012, 10:42 PM   #2
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Nice write-up!

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Old 06-15-2012, 11:45 AM   #3
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Thanks! I actually switched back to bolts because I found it easier. The right pin would get bent from time to time. Otherwise they were nice and lasted over a year.
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Old 06-15-2012, 11:59 AM   #4
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I tack welded the washer to the Clevis pin so that the washer would not wear against the pin's head. It has worked great.
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Old 06-15-2012, 12:17 PM   #5
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Sounds good, I was tempted to do that as well. I meant the lynch pin not the clevis though. I could have switched to a different style of pin I supposed. I Really like the bolt setup I have no, I have my tools with me so it only takes a minute to pop the nut off and yank them out. better than yanking at the pin and ripping my hands up, haha. I only tighten them tight enough that I need a socket on one end. If they over tighten I have plenty of other tools but it hasn't yet. Now that I think about it I wonder why people even invented quick discos, because with regular use the bolt is easy to fasten/remove. The stock with the torx head was annoying though,
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Old 06-15-2012, 12:33 PM   #6
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Same lift, same tires, same disconnects, bigger rock

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Old 06-15-2012, 12:48 PM   #7
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Quote:
Originally Posted by jrmiller View Post
Same lift, same tires, same disconnects, bigger rock

Attachment 132120

mine was in my yard though.

See the Avatar <-----
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Old 06-15-2012, 02:00 PM   #8
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Quote:
Originally Posted by GoldenSahara00

mine was in my yard though.

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Mine was in my yard too! Lol but not really. As always your Jeep looks great. And bonus points for a Sahara
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Old 06-15-2012, 02:01 PM   #9
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Quote:
Originally Posted by jrmiller

Mine was in my yard too! Lol but not really. As always your Jeep looks great. And bonus points for a Sahara
Well of course. I have big plans for this coming year
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Old 06-15-2012, 07:13 PM   #10
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Quote:
Originally Posted by GoldenSahara00

Well of course. I have big plans for this coming year
What are your plans? I know you want an 8.8...I'm hoping to find one too.
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Old 06-15-2012, 07:39 PM   #11
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Quote:
Originally Posted by jrmiller

What are your plans? I know you want an 8.8...I'm hoping to find one too.
Made a new friend who offered to weld me one up actually he already set his own up. But that's on the back burnin for a little. I'm outboarding shocks and high lining front fenders at least. With custom tubes. Then adding 4 inch springs to the front and of course new shocks all around. Then tummy tuck. Then it will be axle time. Finish with steering an brakes and I'll be ready for 37s. Prob gona have to throw in a couple of control arms and other odds and ends but I figure I'll get it all done within the next 5 years I would love to get the hilinea done by the end of July and the shocks by end of summer but $ is tight. Especially with a trip to rausch creek in July. I should pick up some spare shafts for rc too. Blah.
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Old 06-19-2012, 08:35 PM   #12
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Nice job ryan im gunna make me a pair.
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Old 11-24-2013, 08:41 PM   #13
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How did you like these when you had them? I didn't want to dish out the $150 for JKS quick discos so I made a set similar to these yesterday.
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Old 11-25-2013, 12:02 AM   #14
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I did that and hated it. After a while the pin wear, and clunks and squeeks. You also have to keep a check on the washers and pin, as after awhile the pin will wear right through. Here's what I did that works better. Btw im not knocking it, it did the job for me, but I found aj alternative.

I took a flage head hex bolt the same size as the stock bolt, and bought a large wing nut to fit the bolt. I tightened the wing nut as tight as I could by hand, then a little extra with my Gerber tool(which I keep in the jeep). I made a mark in between the "wings" of the wing nut. I flattened the threads a little with a file where I made the mark. Drilled a hole into the bolt, the size of my lynch pin. I put antisieze on the bolt, and put a washer between the end link and wing nut. It stays tight and clunk free and is easy. Pull the lynch pin, loosen the wing nut and pull the bolt. The lynch pin keeps the wing nut from backing off. I can take some pics if anyone is interested. It didnt cost me anything as I already has bolts, and reused the washer and lynch pin from my disco's like the op. You can even use the stock bolt with a wing nut
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Old 11-25-2013, 01:00 AM   #15
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I did that and hated it. After a while the pin wear, and clunks and squeeks. You also have to keep a check on the washers and pin, as after awhile the pin will wear right through. Here's what I did that works better. Btw im not knocking it, it did the job for me, but I found aj alternative.

I took a flage head hex bolt the same size as the stock bolt, and bought a large wing nut to fit the bolt. I tightened the wing nut as tight as I could by hand, then a little extra with my Gerber tool(which I keep in the jeep). I made a mark in between the "wings" of the wing nut. I flattened the threads a little with a file where I made the mark. Drilled a hole into the bolt, the size of my lynch pin. I put antisieze on the bolt, and put a washer between the end link and wing nut. It stays tight and clunk free and is easy. Pull the lynch pin, loosen the wing nut and pull the bolt. The lynch pin keeps the wing nut from backing off. I can take some pics if anyone is interested. It didnt cost me anything as I already has bolts, and reused the washer and lynch pin from my disco's like the op. You can even use the stock bolt with a wing nut
I'd be interested in pictures and maybe a little step by step guide if it isn't too much to ask.
My disconnects are only temporary until I get more time to make a better set over Christmas break or get the money for the real thing.
You can't really go wrong with only spending $6.24 on them
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Old 11-25-2013, 07:20 AM   #16
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I'll put something together this week for you
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Old 11-25-2013, 08:40 AM   #17
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I'll put something together this week for you
Thanks!
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Old 11-25-2013, 09:27 AM   #18
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I did this style only with different pins some time ago. I see that you have the link zip tied to the bar, however you will need to secure the other end up to the body some how or it will droop down and chowder up your tires
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Old 11-25-2013, 09:36 AM   #19
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Just a heads up, I ran this set up for 7 months or so on a 5" lift tj, and the Clevis pin sheered right off one day, and my sway bar was disconnected down the highway! So be safe and check it every now and then
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Old 11-25-2013, 12:08 PM   #20
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This is the best DIY pins I've seen so far.

DIY Swaybar Quick Disconnect Pin

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Old 11-25-2013, 12:39 PM   #21
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This is the best DIY pins I've seen so far.

DIY Swaybar Quick Disconnect Pin

Thanks for that. I am going to try this out on the wife's wj this week.
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Old 11-25-2013, 05:46 PM   #22
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Ok. I get how the bottom part works.
now lets talk about the top of the disconnect.
My Tj has a stud that goes straight up through the sway bar.
there is nothing in the writeup about how to address that situation.
according to the picture it looks like he has the q/d top already in place.
do I need to buy different sway bar links anyways? in that case..... i'm gonna go out and spend a few more bucks and just save myself the headaches.
Rough Country Front Quick Disconnects 1142 (97-06 Wrangler TJ) - Free Shipping 1142 - Free Shipping over $75!

now lets say I already have the q/d then this would be a great replacement in case you lost any parts wheeling.
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Old 11-25-2013, 05:56 PM   #23
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it will move far enough to let you zip tie the link to the coil buckets
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Old 11-25-2013, 11:14 PM   #24
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Sorry guys, never saw any of these posts, I don't get on here much anymore honestly. I went back to a bolt setup a long time ago (2 years~) after maintaining them became a hassle in the long run. I keep 2 drivers w/ the sockets in them right by my drivers seat. It's more secure and honestly it takes about 10 seconds per side to unbolt them. I like having the tools handy too w/ of my small socket sets (I have way too many, always need them) so it's not a big deal for me. A few of the options posted above look really good too, but the way I see it is save money and just unbolt them. Don't be lazy

But if you feel like it make the disco's. Still may not save ya much time in the long run, but you won't have to keep the tools handy.
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Old 11-26-2013, 10:02 AM   #25
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LAZY ? We live in the Age of Microwave Ovens and Cell Phones !!! My 31 year Old Daughter couldn't Boil a Cup of water if it weren't for the Microwave. IT WAS a Glorious day around here when she ventured out on her own.
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Old 11-26-2013, 01:07 PM   #26
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I see you found the bolt don't button. Yes. Don't spend 150 dollars on discos because your lazy was what I was trying to say.
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Old 11-26-2013, 04:21 PM   #27
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I see you found the bolt don't button. Yes. Don't spend 150 dollars on discos because your lazy was what I was trying to say.
No No No, I was TOTALLY in agreement with your statement / train of thought.
SOMETIMES my sarcasm doesn't find it's way to the forefront.

Think about it for a second............................................ ..................
How many folks you know can start a Fire WITHOUT the use of their Gasoline
and Matches, Make a shelter out of Branches / Leaves? Society has gotten
away from the DO-IT-YOURSELF attitude, and moved into that Techno era of
PUSH-ONE-BUTTON and out pops that Roast Beef Sandwich on Rye with the Dill on the Side.
ANOTHER THOUGHT.............. This one might take a little longer.
With the Holidays approaching and Families all gathering around that
Golden Brown Turkey or Honey Glassed Ham, ask the question HOW MANY
at that Table can Bake a simple Loaf of Bread, or a Basket of Home Made,
from scratch mind you, Buttermilk Biscuits.
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Old 11-26-2013, 05:53 PM   #28
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I went back to a bolt setup a long time ago (2 years~) after maintaining them became a hassle in the long run.
I went back to the stock bolts as well. I ran a similar setup to what's shown in this thread, and I didn't like the slop when connected, and it really wasn't much easier to disconnect.

The only thing that sucks about the oem setup is I get anti seize on my hands every time I connect/disco.
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Old 11-26-2013, 07:59 PM   #29
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No No No, I was TOTALLY in agreement with your statement / train of thought.
SOMETIMES my sarcasm doesn't find it's way to the forefront.

Think about it for a second............................................ ..................
How many folks you know can start a Fire WITHOUT the use of their Gasoline
and Matches, Make a shelter out of Branches / Leaves? Society has gotten
away from the DO-IT-YOURSELF attitude, and moved into that Techno era of
PUSH-ONE-BUTTON and out pops that Roast Beef Sandwich on Rye with the Dill on the Side.
ANOTHER THOUGHT.............. This one might take a little longer.
With the Holidays approaching and Families all gathering around that
Golden Brown Turkey or Honey Glassed Ham, ask the question HOW MANY
at that Table can Bake a simple Loaf of Bread, or a Basket of Home Made,
from scratch mind you, Buttermilk Biscuits.
I got ya. I was raised with a good work ethic and taught responsibility from my parents but hate seeing that attitude in those around me. Ill use things to make life easier but don't take them for granted and I'm not afraid of hard work.


Definitely easier w just the bolts man. I don't use anti seize. No problems.
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Old 11-26-2013, 08:47 PM   #30
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I think the best way to do it is to replace the bolt with a hex head, and keep a socket set with you. It will only take a few seconds to disconnect

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