RE Quick Disconnects For The TJ
By Shawn Pagan
1. Purchase @ least 4 additional ½” body washers you may or may not need them, but if you do….
Everyone I know has needed at least 2 additional washers then what comes
with the kit from Rubicon Express, I recommend 6 additional washers (4
that you need to purchase and the original two that come off your
existing lower sway end link bolt.
2. Tools Needed (real basic – nothing fancy, although a vice becomes real handy)
· Ratchet (although one could do this with simple wrenches, but it would be tougher)
· Breaker Bar
· 11/16” socket
· 5/8” socket
· ¾” socket
· ¾” box end wrench
· 15 mm socket
· 19 mm socket
· #56 Torx socket (#55 works okay if you use it to simply hold the Torx bolt and remove the nut with a ratchet. I note this because most sets do not include a #56)
· Wood block (old piece of two by four or anything solid, but soft)
· Hammer (a small body sledge works great)
· Small vice
· Silicone Lube (WD-40 will work but some people don’t recommend it for urethane)
3. Remove front frame cover
· 2 Bolts Each Side 3/8”
4. (Starting on the drivers side) Unbolt top of sway bar end link
· should be a 5/8” nut
· 1 nut each side
5. Repeat passenger side
6. Unbolt lower sway bar end link
· #56 Torx and a 19MM Wrench
· completely remove nut and tap bolt out
7. Repeat passenger side
8. Unbolt sway bar and remove (this really is easier than trying to do it on the vehicle with a pickle fork, and probably takes less time)
· 4 bolts on the top of the front frame
· 15MM (Note: for the rear bolts a 3/8” drive ratchet works best. It is somewhat tough to get a ½” drive in without possibly damaging you paint)
9. Remove the sway bar upper link
Repeat other side.
11. Replace sway bar on vehicle. Be sure to snug up bolts but do not tighten.
· Note: sway bar ends should point up when the bar is held parallel to the bumper
12. Install sleeves into bushings
· Lube each reducer sleeve (qty. 4) and each urethane bushing set (qty 4)
· Using the vice press the reducer sleeve into the bushings. Be sure to keep even pressure as the bushings are actually two pieces and when the spacer gets to the center it can force the other busing out.
· Turn the bushing / spacer unit around in the vice and repress to make sure the bushings and spacers are firmly seated.
· At this point you may want to visually inspect each busing / spacer assembly to make sure the bushings were not distorted or pushed out unevenly.
13. Return to vehicle and install the upper sway bar link bracket
· Using the 11/16” lock nut and small washer supplied with the kit
· Again snug but do not tighten
14. Repeat passenger side
15. Install bushing / reducer assembly as follows
again snug up but do not tighten
16. Repeat passenger side
17. Install lower end link adapters as follows using the supplied ¾” lock nut, bolt, and spacer
· Note: Make sure as you snug this up that the pin on the bushing does not get stuck in your spring!
18. Repeat passenger side
19. Turn bushing pins so that they face each other and align the sway bar.
· You may have to rock the sway bar up and down to get it to slide side ways
· Note: the top pin will align slightly toward the inside of the vehicle. This seems to be normal.
· Verify alignment is equal on both sides, additional washers can be used as spacers, but keep in mind whatever change you make it to both sides….
20. Insert disconnect center sections, install snap pins
21. Repeat passenger side
22. Tighten sway bar frame mount bolts
23. Check to make sure pins still slide freely and do not bind
24. Tighten 11/16” nut on top of upper adapter.
25. Check to make sure pins still slide freely and do not bind
26. Repeat passenger side
27. Tighten upper bushing bolt
28. Repeat passenger side
29. Tighten lower bushing bolt
30. Repeat passenger side
31. Check to make sure pins still slide freely and do not bind
32. Replace front frame cover
33. Test drive
34. REMINDER: After driving for 30-50 miles it may be prudent to check and make sure everything is tight and not binding.
35. Disconnect and flllleeeexxxx….
36. Reinstalling the pins will get easier as you get used to it, but slightly tapping the sway bar down usually helps. And always make sure your sway bar is centered, I have noticed that it can slip a little side to side when disconnected.