Converting The E-Disco To Manual
 

Here are some pics of how the conversion to manual control was done.
Go here to review how it works in its stock configuration:
https://www.jk-forum.com/forums/show...rtbar%29-Study.

http://i776.photobucket.com/albums/y...rtsRemoved.jpg

http://i776.photobucket.com/albums/y...dwithCable.jpg

http://i776.photobucket.com/albums/y...ughShifter.jpg

http://i776.photobucket.com/albums/y...hroughCase.jpg

http://i776.photobucket.com/albums/y...terInPlace.jpg

http://i776.photobucket.com/albums/y...leaseCable.jpg

Here is a clip of the progress on the lever.
It's a mock-up using an XJ console I had in the barn. I won't be installing the sway bar/lever into my JK until the electronic one fails.

The piece of track hanging from the bar simulates the bar being loaded from the Jeep being on uneven ground. As the Jeep moves, the bar will unload, and release. The lever will remain in the release position from being over-center.
When moved to the reconnect position, the lever will be free until the splines on the bar line up. It will be obvious when the bar reconnects, as the lever will be held in the forward position.
Watch the lever as the bar reconnects. You will see it move forward.


http://i776.photobucket.com/albums/y...h_MVI_0395.jpg

Glorious real world exploded view and write-up as always. Looking forward to seeing the finished product.

Looking good! Nice job.

Good ole Maine ingenuity : )

See post #2 for a clip of the lever in action. Let me know if the lighting is adequate, and how it plays.

looks good! i'll definitely be going this route if/when mine ever dies. amazing work :thumbsup:

Same here when my electrical is all done I will do this!

Awesome work man!!!!!

no if about it, your e disco WILL fail, its just a matter of time and environment. If you live in the desert, long time, anywhere water hits the front of your jeep, failure is imminent. chrysler should be hammered about this, its an unbelievable engineering screw up.