Introduction: Toolless Jeep TJ Sway Bar Quick Disconnects
Want easy to use well made sway bar quick disconnects for under $50? Good youre in the right place. These disconnects work the same as those offered by Steinjager. We will re-use the upper ball joint and connecting rod of the sway bar end link. The factory upper joint of the end link will not allow the end link to be folded flat against the sway bar, however with both end links disconnected we can rotate the sway bar up and use zip ties to hold the sway bar and end links out of harms way. I have included links to the required hardware in the list below.
You will need:
2. 1/2" washers - your favorite local hardware store or McMaster
3. one pack of 1/2"-20 stainless jam nuts (i used stainless to avoid rust)
5. 1/2"-20 one inch hex right hand threaded die. (local tool supplier, hardware, etc)
*this dies is on McMaster but they only carry a really nice one that is a little pricey. I bought one locally for $6
6. An angle grinder and cutting disk, or a hack saw.
7. 18mm socket
8. 15mm socket
9. T55 star bit
Step 1: Remove Bottom End Link Bolt
Remove this bolt using a T55 star bit and an 18mm wrench. You will likely want to use some wd40 and a breaker bar or impact wrench to break the nut loose.
Step 2: Press Out End Link Top Bolt
I recommend removing and assembly of the end links one at a time. Having one end link still installed will make installation of the completed end link easier. There is a tip in the last step that will require one of the end links to still be installed.
The top bolt in the end link is press fit and requires a puller and 15mm socket. Remove the nut completely before pressing the bolt out of the sway bar or the nut will spin the bolt when you attempt to remove the nut.
Use a ball joint separator tool to press out the top bolt without damaging the bolt or the boot on the joint.
Step 3: Cut the Bottom Joint Off of the End Link
Using a hack saw or angle grinder and cutting disk cut this bottom joint off of the end link. Cut as close as possible to the joint so you have enough rod to create threads in the next step.
If you don't own and angle grinder an inexpensive hack saw will cut through this in just a few min time.
Step 4: Thread the End of the End Link
Using a 1" hex 1/2"-20 die, 1" socket, and a ratchet thread the bottom end of the rod. Make certain the die is facing the correct direction. The forward side of the die will be labeled.
Apply pressure to the back of the ratchet with one hand and slowly turn the ratchet with the other hand until the die begins to cut threads and can hold itself on the end link.
Remove the socket and apply a little oil to the rod, this will make cutting threads much easier. Continue to rotate the die until threads are cut all the way up to the first bend in the end link. You should have about an inch of threads.
*tip - when turning the die if resistance begins to increase as your cutting threads, stop and rotate the die backwards 1/4 turn. This will help the die eject any metal shavings that are clogging the die. Continuing to force the die forward can break the die.
Step 5: Thread on the Jam Nut
Step 6: Thread on the Quick Disconnect Ball Joint
Once the jam nut and Quick disconnect ball joint are threaded all the way on, orient the ball joint the same direction the original lower joint was facing and tighten the jam nut towards the ball joint to hold it in place.
Step 7: Install on Your Jeep
Remove the ball from the quick disconnect and thread it through the original mounting point on the axel. It should be a snug fit. Add one 1/2" washer and 2 stainless jam nuts behind it.
Tighten the first nut to the bracket to hold the ball in place. Tighten the second nut against the first nut so they cannot come loose.
Insert the top end link bolt back into the sway bar and attach the new quick disconnect ball joint. Fasten the top bolt back in place with the original nut. If the top bolt spins when you try to tighten down the nut, jack wheel you are working nearest an inch or two in the air with opposing end link still connected. This will apply just enough pressure to the press fit upper end link bolt into the sway bar to prevent it from spinning.
Once Both sides are complete have fun wheeling :D