Seized Sway Bar Disconnect Repair


TargetOz

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Jul 14, 2021
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39
Location
Mudgee NSW
I purchased my Rubicon and wondered why it didn’t disconnect. My first thoughts were that the internal connector was seized, well upon inspection it was, but that’s kind of an easy fix, pull apart, wire wheel all the rusty parts reassemble with grease. But my problem was the bearings in the disconnect housing halves were seized so basically buy a new complete bar…or fix it. So have a look at the pictures for some reference.

What I’ve done was dissemble both halves and face them down then everyday for a few weeks I’ve sprayed WD40 at the seals so that the fluid soaks down into the seized bearings. Then start to tap the halves back and forth with a hammer to get things moving. After 2 weeks I’ve managed to get it to move 3”. Soak with WD40 again but next time you attempt to move it to loosen up the bearings place the housing/s in a vice and start working on moving the bar this time.

Once you get it fully moving you will need to clean the rusty mud out so spray lots of cleaning fluid like brake cleaner etc then once it’s clean finish off by putting in more WD40.
 
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TargetOz

TargetOz

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Mudgee NSW
Nice job. Did you replace the bearings? Pictures !!!!
No, I’m hoping to fully recover the bearings as it looks like I need a 3 legged puller to pull the connect gears off to get to the bearings, that’sa lot more work, but it may be a necessity will tell in time.
 
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TargetOz

TargetOz

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Couple of short videos showing the progress
 

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TargetOz

TargetOz

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Quick update, success! Full rotations, not long now will be good as new

image.jpg
 

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TargetOz

TargetOz

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Update on my sway bar repair, all good now reassembling and posting a vid of gasket making

image.jpg
 

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TargetOz

TargetOz

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Mudgee NSW
And the finished product, PS I used engine oil as the lubricant for the disconnect gears because grease is too heavy and eventually will slow down the operations as the grease gets old. Engine oil is a lot like the oil you use in your gearbox except thinner.
 
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