Is little end play on the Rubicon sway bar disconnect normal? Mine has about 1/2 of an inch of play when locked up not making highway driving any easier kind of rocks around. I would invest in a replacement unit if it was tighter then this one. Last time I had the thing apart to re-grease it the gears didn't look that warn maybe these are just poorly designed with lower tolerance doesn't take much gear play to translate to lot of movement at the end of the bar where it attaches to the axle. I have manual disconnects also because the auto one still limits my axle. The only reason I retain the stupid thing is for resale value.

 

I have one on my Sport, and yes, they do have play.
Can't say it effects the road manners on mine anyway

 

I since found another forum had lot of discussion on this subject and seems this is normal gears are cut in such a way it helps with locking it up. I need to re-setup the control arms get little more positive caster not as easy as I thought to adjust it the control arms the axle tends to want to do it's own thing getting it to rotate a few degrees isn't that easy.

 

[QUOTE=kell490;4382435 I need to re-setup the control arms get little more positive caster not as easy as I thought to adjust it the control arms the axle tends to want to do it's own thing getting it to rotate a few degrees isn't that easy.[/QUOTE]

Jack under the pinion flange/yoke to decrease caster (raise pinion) or jack under the diff to increase caster (lower pinion) and help get the bolts lined up again. When adjusting control arms it's often helpful to have 2 jacks, one in each place.