Sway bar disco motor

[joss097]

I was looking for a thread on rotating the disconnect motor for more clearance but cannot find it. Do anyone have info on doing that. I remember that it can be done on PowerWagon and want to know if it's possible with the JK.

[wayoflife]

The only JK I have seen this done on is Kilby's. If memory serves me right, it required some fabing of a bracket and rubber hanger. However, there was no real explination beyond that provided. Sorry.

[joss097]

So we can assume that you will surely find something when you got yours! Maybe someone at Kilby's (or someone else) have some idea of producing a kit for this.

[wayoflife]

Kilby will be providing a kit that is included with their new front bumper which also comes with a skid plate to protect it. The only thing is, you will have to cut off the lower cross member in order to install his bumper if memory serves me right.

[cwalker]

I was looking for a thread on rotating the disconnect motor for more clearance but cannot find it. Do anyone have info on doing that. I remember that it can be done on PowerWagon and want to know if it's possible with the JK.


It can be rotated up and out of the way by relocating a bolt hole. It doesn't require a new bracket either.

Here's how:

You'll need the following:
16mm socket (for swaybar bushings bolts)
15mm wrench (for disco unit hanger bolt)
a 'new' bolt: 12mm or 1/2" x 5" long (min length would be 4.5")
a drill and tap to match your bolt

1. Turn wheels to the right.
2. Located hole to be drilled and tapped. (see pic 1.)
3. Drill and tap hole for 12mm or 1/2" bolt. (I used the larger 1/2" and it worked fine.)
4. Remove the bolt that attaches the disconnect unit to the rubber hanger. (see pic 2.)
5. Remove the 4 bolts that hold the swaybar to the frame. (see pic 3.)
6. Unplug the Swaybar disconnect wiring hardness. (The large one that connects to the sway disco unit.) and unclip the harness wires from the zip-tie.
7. Push swaybar towards the rear of the Jeep. (you don't have to disconnect it from the axle.)
8. Rotate the disconnect unit forward approx 90degs.
9. Replace rubber hanger bolt with new bolt, and attach to new hole. (minimum bolt length = 4.5") (see pics 4 and 5.)
10. Reconnect swaybar to frame.
11. Reconnect disco unit wiring harness.

Notes:
-The rubber hanger stud that extends from the swaybar bushing bracket can be bent for a proper fit once the unit is in its new location.
-I used a 1/2x4.5" bolt, which is why the hanger bushing is slightly angled... a 5" bolt would be the correct length to use.
-A winch that sits between the frame rails may interfere with the rotated unit. (There's still lots of clearance for a winch, but who knows. :) )

Sorry for the terrible pics... camera phone.

SEE POST BELOW FOR BFORE AND AFTER PICS

[cab76]

It can be rotated up and out of the way by relocating a bolt hole. It doesn't require a new bracket either. Sorry no pics right now, I might be able to post some this weekend... if there's enough interest.

The only thing you'll need is a longer bolt (to replace the one that goes thru the rubber hanger) and a drill and tap to match the tread for that bolt. (and tools, of course.)

1. Unbolt 4 bolts from swaybar bushings and let it drop down. (the ones connecting it to the frame.)
2. Disconnect plastic clip securing wiring to disco unit. (just the one holding the wires, not the main plug)
3. Remove the bolt that goes thru the rubber hanger and screws into the disco.
4. Rotate disco unit towards the front of the Jeep to locate hole to be drilled.
(there is already a tab on the disco unit with a cast hole that lines up with the rubber hanger bolt hole when rotated. It's obvious which one it is... maybe DC engineers already planned on using the hole for this reason??)
5. Rotate back down to drill and tap hole in housing.
6. Rotate back up and secure in place using longer bolt.
7. Secure wiring.
8. Rebolt swaybar to frame.

I had the bumper off when I did this, and have since moved it back to the stock location to fit a winch between the frame rails.

Please post pics! Relocating up is a great alternative to a skid at this location, in my opinion.

[joss097]

I had the bumper off when I did this, and have since moved it back to the stock location to fit a winch between the frame rails.


So you cannot put the winch betwwen the frame with the disco in the up position? Too bad if it's that:naw:

Post pics please

[cwalker]

Please see edited post above for "how to".

Here are a few extra before and after pics.

So you cannot put the winch betwwen the frame with the disco in the up position? Too bad if it's that:naw:

Post pics please

There's lots of clearance even when it's rotated, but it prob just depends on which bumper you choose.

[BeerMonkey]

awesome. now i need to figure out what to tell the wife about me taking off the bumper already. not to get to off topic but whats the blue thing in the background in the last pic?

[Quebec4x4]

Remove it, remove crossmember ... and put Anti-rock !!

:yup:

[cwalker]

awesome. now i need to figure out what to tell the wife about me taking off the bumper already. not to get to off topic but whats the blue thing in the background in the last pic?

:) Yeah, I've been driving around without a bumper for the last few weeks. My wife has just gotten used to it. I think the JK's look better without a front bumper, as opposed to the stock piece. imo

The vehicle in the back is a Terracruzer. (feel free to delete this Eddie, if I crossed a line in saying that... don't think I did.)

[BeerMonkey]

ok so whats a terracruizer?

[cwalker]

ok so whats a terracruizer?

Terracruzer... It'a a custom buggy. Sorry to be so vague, but I work for the company that builds them and don't want to get accused of pimping product, and I'm not sure of the protocol here. Anyway, just google it. -Sorry

[low4life]

Ok this may be a dumb question but Ive got to ask since I plan on getting a rubicon and lifting it with a 3 inch lift why would you want to do this rotating of the disconnect motor. Is it for more clearence or because of the lift.:confused:

[wayoflife]

Ok this may be a dumb question but Ive got to ask since I plan on getting a rubicon and lifting it with a 3 inch lift why would you want to do this rotating of the disconnect motor. Is it for more clearence or because of the lift.:confused:

The e-disco motor hangs very low to the ground and is vulnerable to rocks. Rotating it up may give you a bit more clearance.

[low4life]

ok but you dont have to inorder to do a lift kit. Thats good cause it'll be undr warranty anyways so for the first 3 years if it gets hit or broken its jeeps problem to replace

[JulietKilo]

Bump for a cheap clearance fix. This is a great writeup!

i would like to add that all the new jeep bumpers are ugly except for maybe AEV. The new bumpers all hang way too low and clearance becomes an issue and they are ugly hunks of metal. This will fix that. Move the disconnect up and out of the way and make a low profile bumper with a flat skid for the disconnect motor.

[red5]

I added 2 zip lock freezer bags over mine staggered with zip ties to keep them closed. Why???

Well I noticed that my sway bar disconnect connector is now on the top and not the bottom. Mine happens to be cracked a little (who would have thought a rock could break plastic! :eek2: ) Which means rain, ice, sand, etc... can not only get in there but "sit" in there now as well. When it was on the bottom it would "auto" drain.

Cracked or not you might want to bag it as well. You don't want water "sitting" in/on the connector and it cost me all of $0.00 Since most jeepers have zip ties and zip lock freezer bags where in my kitchen. :yup:

just my .02

[Jamooche]

What is the actual inches in clearance gained by rotating the motor?

Does this void the swaybar system warranty, or any other warranty?

I believe only the Kilby and Expedition One bumpers work with this rotation mod. Anything else out there?

I plan on a 2" Superlift lift and keeping stock tires for now. Is it worth doin this motor mod?

[Woods]

I took a slightly different approach on this one. I purchased a 10mm bolt that was about 4.5" long, and a 10mm nut. I drilled the nut out so that I could slide it over the non threaded part of the bolt. I then welded the nut to the bolt on one side. I had to turn the head of the bolt down, so I could get the rubber hanger to slide over it.

RE warranty. If there was ever an issue, just keep the original bolt so you can rotate the motor back into the factory location. The clearance gained is pointed out in the second picture.

http://img249.imageshack.us/img249/6321/minidsc4820mm9.jpg (http://imageshack.us)

http://img165.imageshack.us/img165/9094/minidsc4821copylf2.jpg (http://imageshack.us)

[SabrToothSqrl]

seeing as how this is such a no brainer... did jeep fix it in the 2008s?

looking at it factory it looks like its begging to get ripped off :(

[RubiconOrdie]

Not sure I really see the point of this except to maybe keep the wires from being pulled. If I hit something that will rip my motor off I'm not more than a couple inches fron seriously damaging my drag link, track bar, tie rod and then axle. Wouldn't it be easier not to straddle a big rock or something your just plain not going to clear? I guess I can see if your going to drive straight over a big log or something.

Now that I've said it I'm probably going to damage it this weekend.

[Jamooche]

Thanks Woods for the info and excellent photos. It's a lot more simple to move than I thought it was. I like the Kilby bumper, but am leaning towards the Expedition One due to price.

RubiconOrdie - I totally see what you are saying. I'm still debating whether to buy a bumper/skid plate that requires rotating the motor. If the system has a problem, it looks like it's as simple as removing the skid and rotating it back for warranty work. It does add quite a bit of clearance though.

Does anyone have good photos of this mod with the bumper and skid on, or going over obstacles etc??

[Graluc]

It's been almost a year since I rotated mine up. Haven't had any trouble out of and I've been on many wheeling trips. :D

http://www.jk-forum.com/showthread.php?t=2869

[MikeyLikesIt]

It's been almost a year since I rotated mine up. Haven't had any trouble out of and I've been on many wheeling trips. :D

http://www.jk-forum.com/showthread.php?t=2869

Nice writeup and photos.

I agree with RubiconOrdie...But, if you slide off a rock etc., or hit something unavoidable, I'd rather replace a draglink than a draglink AND the disco motor.

Good thread...and my next mod.

Mikey

[JulietKilo]

seeing as how this is such a no brainer... did jeep fix it in the 2008s?

looking at it factory it looks like its begging to get ripped off :(

Nope, I have an 08. Still the same.

[MELONHED]

Got a question. From what I gather, it's being said, in other threads, that if you rotate the e-disco motor up, you will not be able to use a bumper with a recessed winch mounting. It this true. Looking at the pictures of the Expedition One Basic DX with the new foglight endcaps, they are on a Rubicon with a recessed winch. Can't tell if they have the skid plate mounted or not, but if they do, the motor is rotated up. I'm confused, anybody got this setup with winch on a Rubicon. Can you rotate the e-disco motor up with a recessed winch? :thinking: