hello! Have been a lurker for years and have benefited greatly from reading the groups expertise. I was wondering if anyone could offer some advise on a recurring problem I have.

I have a 2007 JKU X, lightly modified with a 2.5" lift, 32" tires, steel wheels. I am repeatedly bending the sway bay link mounting tabs on my front Dana 30. The tabs bend to about 45 degrees towards the tire. Was happening with stock links, still happening with JKS quick disconnects. I notice the bend getting worse when death wobble starts, heat it up/ bend it back, then good for another few thousand miles. Doing this repeatedly is getting old. Anyone have any idea why this is occurring?

 

The axle side tab is bending? You could weld on another tabor reinforce it with a similar.

Are you not at all disconnecting the sway bar when offroading? What kind of offroading?

Sounds like you might want to fix that death wobble problem also. I doubt there related.

 

You've fatigued the metal at this point, so it will keep bending. Cut the stock tabs off and weld some new ones made out of 1/4". You could also try to double shear the stock one or new one.

Death wobble has nothing to do with the sway bar. That means you have issues somewhere else. For example, worn ball joints, TREs, etc.

 

I hear you, but the bend gets worse, the DW proportionally gets worse. I ignored it as not possibly having anything to do with DW for forever. Replaced ball joints, all bushings, alignment, tires, wheels, unit bearings- basically anything I could think of to fix the @&$! DW. Last thing I did was bend that stupid tab back out as an afterthought one afternoon, and bam- DW gone. Have no idea of the why, just know it was gone after that. Noticed the wobble coming back recently, found tab bent again.

Not saying it makes sense, just saying what it's doin.

 

What size tires? Ive had dw a ton. From bjs, control arm bushings, track bar bushings, tire balance and such. Alot can cause it and sometimes its a pain to narrow down.

 

32" Mickey's on 17" steel.

 

I don't even run sway bars. I'll never say something is impossible, but there should be no connection between the two issues. However, if it prevents the DW, so be it. Either double shear the mount or put a new one on that is beefier.

 

Figured that's what I'd do, my question is does anybody know why this is happening? I can't figure out what is causing the twisting that causes the bend.

 

Probably just weak. Sway bars whole point is to pull/push the axle which is fighting against it so to speak when its trying to articulate. Thats a thick swaybar.

 

How much room between bump stop and axle? I bent mine once, I had bumpstop extensions and could only get a finger or two between them. I thought I was gonna miss this hole, but I didn't and my jeep hit it so hard, bigger than I thought too, it bent the tab and my sway bar end link. I could see it bending from DW, but not causing it. Need to check all your bolts. I would weld on either a thicker piece or a truss. Like a triangular 3/8" piece to it and the axle. I always thought they were weak. Found out the trackbar bracket is weak. Just replaced it.