How to Install Zone Offroad Front Sway Bar Quicker Disconnect (87-95 Wrangler YJ) on your Jeep Wrangler

CONGRATULATIONS on purchasing new Bar Pin Eliminators from JKS Manufacturing. We are committed to providing you with the best products available and your satisfaction is our first priority.

PLEASE READ these Installation Instructions carefully, and save them for future reference, as they contain important installation and maintenance information.

Important

NOT COMPATIBLE WITH aftermarket swaybars. Install product with Original Equipment swaybar only.

SOME VEHICLES MAY REQUIRE extended front brake hoses or other modifications to compensate for additional suspension travel.

NEVER DISCONNECT swaybar when operating vehicle on public roads.

WHEN DISCONNECTED, the Quicker Disconnects must be completely removed from the vehicle and the swaybar must be secured to prevent interference with other suspension components or axle.

1. REMOVE ORIGINAL EQUIPMENT (OE) SWAYBAR LINKS

Remove front swaybar drop links and mounting hardware per the factory service manual instructions for your vehicle.

2. INSTALL UPPER TAPERED POST

Mount the tapered Upper Stainless Steel Post (C) on outboard side of the swaybar, ensuring small Click Pin holes are horizontal or parallel with the ground.

Apply medium strength threadlocker to the tip of 1/2” x 1-3/8” Bolt (A).

Secure tapered post to swaybar by inserting the 1/2” x 1-3/8” Bolt (A) and 1/2” Lock Washer (I) from the inboard side and tighten to 65 ft-lb. using a torque wrench.

HINT: A small Philips head screwdriver or punch inserted into the Click Pin hole will enable you to prevent the Stainless Steel Post from rotating when tightening the mounting bolt.

3. DETERMINE MOUNTING LOCATION FOR WELD-ON TAB

It will be necessary to weld the lower mounting tab directly to the front axle housing. The base of the tab can be positioned in the 2-, 3-, or 4-o’clock configuration as viewed from the passenger side (8-, 9-, or 10-o’clock from the driver side). HINT: The position of the mounting tab will depend on the vehicle and amount/type of suspension lift installed.

HINT: For easiest operation, the tapered mounting post should point forward as illustrated in the 2- or 4-o’clock configuration. Alternatively, a perpendicular mounting position (as illustrated in the 3-o’clock configuration) may also be utilized in tight clearance applications.

To determine the proper location for the lower mounting tab, temporarily slide the Upper End (G) of Quicker Disconnect onto the Upper Stainless Steel Post (C) and adjust angle of swaybar to Acceptable Range (0°-10°). HINT: Refer to Step 6 on next page for illustration of swaybar angle.

Temporarily insert the threaded end of Lower Stainless Steel Post (L) into Weld-on Tab (J) and secure with 1/2” Nylock Nut (K). Slide tab and post assembly into Lower End (H) of Quicker Disconnect.

Choose the configuration for the Lower Mounting Tab that allows the Quicker Disconnect to be installed as close to vertical as possible. Length of Quicker Disconnect may be adjusted as long as it does NOT exceed Maximum Length of 9-3/8” (measured from bushing centers).

Mark the location on the axle tube where Weld-on Tab (J) will be installed.

4. MOUNT WELD-ON TAB TO AXLE TUBE

Remove tab and post assembly from Lower End (H) of Quicker Disconnect and disassemble.

Remove paint from axle tube where Weld-on Tab (J) will be mounted and clean area thoroughly.

Weld lower mounting tab to axle tube so that Stainless Steel Post – when installed – is horizontal or parallel with the ground.

Paint Weld-on Tab (J) and any bare metal on axle tube with spray paint to prevent corrosion.

5. INSTALL LOWER TAPERED POST

Re-insert threaded end of Lower Stainless Steel Post (L) into Weld-on Tab (J). Tapered end of post must point forward or outboard, depending on the mounting configuration chosen.

Secure Stainless Steel Post (L) with 1/2” Nylock Nut (K), ensuring small Click Pin holes are horizontal or parallel with ground.

Tighten 1/2” Nylock Nut (K) to 65 ft-lb. using a torque wrench. HINT: A small Philips head screwdriver or punch inserted into the Click Pin hole will enable you to prevent the Stainless Steel Post from rotating when tightening the mounting bolt.

6. SET QUICKER DISCONNECT LENGTH

Adjust the length of your Quicker Disconnects until swaybar is at the Ideal Angle or within Acceptable Range. Vehicle must be at normal ride height and located on level ground.

IMPORTANT: DO NOT exceed Maximum Length (measured from center-to-center of bushings) indicated for your part number.

Once adjusted, lay Quicker Disconnects on a flat surface and tighten Jam Nuts (M) firmly against the Lower Ends (H).

IMPORTANT: Bushing cradles at both ends of Quicker Disconnect must remain parallel with their respective mounting posts when Jam Nut is tightened.

7. INSTALL QUICKER DISCONNECTS

Slide Upper End (G) of Quicker Disconnect onto the Upper Stainless Steel Post (C) and Lower End (H) onto Lower Stainless Steel Post (L).

Insert Click Pins (D) as illustrated to secure.

IMPORTANT: When properly installed, the ring on the Click Pin will “snap” against the shaft of pin. When installed backwards, the ring does not fit snugly against shaft.

8. LUBRICATE QUICKER DISCONNECTS

Lubricate all Grease Zerk fittings (E) on the Quicker Disconnects immediately after installation using common wheel bearing grease or equivalent.

Troubleshooting

If swaybar does not rotate freely, remove from vehicle, clean and apply rubber lubricant to chassis-mounted bushings, and reinstall.

Maintenance

It is important to lubricate Quicker Disconnects frequently for the first three (3) months after installation to evacuate contaminants that may build up during break-in period.

After break-in period, Quicker Disconnects should be lubricated regularly as part of vehicle maintenance schedule.

Regular cleaning with pressurized water is recommended to maximize ease of operation and reliability. Always lubricate afterwards to evacuate any moisture.