Quick Disconnects PART #: RC-SB500-UV APPLICATION: JK, XJ, TJ, LJ, WJ, YJ, CJ, FSJ

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1 Quick Disconnects PART #: RC-SB500-UV APPLICATION: JK, XJ, TJ, LJ, WJ, YJ, CJ, FSJ INTRODUCTION Rusty s recommends that this installation should be preformed by a certified automotive technician or a person with professional mechanical knowledge. Installing this kit with out this expertise may jeopardize the handling and safety of the vehicle. Read instructions several times before starting. Be sure you have all needed parts and know where they install. Read each step completely as you go. Some vehicles may require extended front brake lines or other modifications to compensate for additional suspension travel. Never disconnect sway bar when operating a vehicle on public road. When disconnected, sway bar must be secured to prevent interference with other suspension components or axle. Start the install with the vehicle on level ground and the vehicle at static height. Be sure you have all needed parts and know where they install. Read each step completely as you go. 1. Place the vehicle on level ground, with the suspension at normal ride height. Place the vehicle in Park or First gear, and set the parking brake. Chock the tires to prevent possible vehicle movement. 2. Remove the sway bar links at the sway bar end then remove the sway bar link hardware at the axle end. Some may have a pressed-in bolt present, which may require lubricant and then pressing it out. Disregard this hardware, it will not be reused. NOTE: This instruction form covers a wide range of vehicles. Please refer to the section that covers the specific steps for your vehicle now. TJ / XJ / ZJ 3. (Figure 1) Locate the upper U-shaped bracket for the Rusty's disconnects. Position this bracket under the end of the sway bar and install the supplied hardware from the bottom, going through the bracket first, followed by the sway bar. Place the supplied washer on the bolt, followed by the supplied Nyloc nut. Do not fully tighten at this time. Figure 1

2 4. Install the bullet pin (Figure 2). Position the bullet pin on the factory sway bar mount on the axle. The pin should be positioned on the inside of the mount, facing inward. Secure the pin to the sway bar mount using the supplied nut. For further clarification, the nut should be facing the tire on the vehicle. Rotate the bullet pin so that the hole for the quick pin is easy to access. Use a small screwdriver in the quick pin hole to prevent it from spinning, and tighten the nut to 60 lb-ft. Place the urethane spacer on the pin as shown. Figure 2 5. With the 5.5 lift or more, may require a slight modification at the axle end sway bar link mount. If the tie rod/draglink looks like it will come in contact with the sway bar link mount, you will need to bend the tab outward 10 degrees. The easiest way to do this is by using a large adjustable wrench. 6. Install the disconnect (Figure 3). If not already installed, push the supplied aluminum sleeve into one end of the disconnect. Attach the now sleeved end of the disconnect to the upper U-shaped bracket on the sway bar using the supplied hardware. Do not tighten at this time. Position the other end on the bullet pin on the axle. 7. Refer to Figure 6 for setting the operating angle of the sway bar. The threaded center portion of the disconnect is a right hand/left hand (turnbuckle) style thread. Loosen the jam nuts and rotate the center portion of the disconnect to adjust the angle of the sway bar until it matches the angle noted in the chart for your vehicle. Apply a small amount of Loctite to the threaded portion where the jam nuts will be locked down, then tighten the upper and lower jam nuts. 8. Position the upper mounting bracket so that the disconnect mounting bolt is parallel to the axle / vehicle grille. Tighten the upper disconnect bolt, followed by the bracket-to-sway-bar mounting bolt. 9. Grease the fittings with half a pump per fitting. 10. Repeat these steps on the other side. 11. Refer to the Final Steps to complete the installation. Figure 3 JK / WJ / YJ / CJ / FSJ 12. (Figure 4) Remove the U-shaped bracket that has been pre-installed on the disconnect; this bracket will not be used. Also remove the aluminum sleeve (if present) in one end of the disconnect. This sleeve can be lightly tapped out of the disconnect with a small punch and a hammer. 13. Install the bullet pin on the sway bar (Figure 5). Attach the bullet pin to the disconnect as shown and attach it to the sway bar. The bullet pin and disconnect should be facing outward (towards the outside of the vehicle). Secure the pin to the sway bar using the supplied nut. For further clarification, the nut should be facing the center of the vehicle. Rotate the bullet pin so that the small hole for the quick pin is easy to access. Using a small screwdriver in the quick pin hole to prevent it from spinning, tighten the nut to 60 lb-ft. Figure 4

3 14. Install the remaining bullet pin on the axle. Position the bullet pin on the factory sway bar mount on the axle. The pin should be positioned on the inside of the mount, facing inward. Secure the pin to the sway bar mount using the supplied nut. For further clarification, the nut should be facing the tire on the vehicle. Rotate the bullet pin so that the hole for the quick pin is easy to access. Use a small screwdriver in the quick pin hole to prevent it from spinning, and tighten the bolt to 60 lb-ft. Make sure the supplied urethane spacer is present on the pin, then slide the other end of the disconnect on to the bullet pin and secure with the supplied spring-loaded quick pin. 15. Loosen the jam nuts on the disconnect and rotate the center portion of the disconnect until the disconnect is fully compressed (screwed all the way in). Refer to Figure 6 for setting the operating angle of the sway Figure 5 bar. Rotate the threaded center portion of the disconnect until the angle of the sway bar matches the angle on the chart for your vehicle. Apply a small amount of Loctite to the threaded portion where the jam nuts will be locked down, then tighten the upper and lower jam nuts. 16. Install the quick pins to secure the disconnects on the vehicle. 17. Grease the fittings with half a pump per fitting. 18. Repeat these steps on the other side. 19. Refer to the Final Steps to complete the installation. ZJ Grand Cherokee 10º TJ Wrangler XJ Cherokee 15º YJ / CJ 5º WJ 30 JK 0 Side View Horizontal Pivot Point Figure 6

4 FINAL INSTALLATION STEPS 20. If not done already, secure the Quicker Disconnects to the bullet pins using the supplied springloaded quick pins. 21. Double-check all hardware for proper torque. Cycle the suspension and verify proper clearance and operation of all components. 22. NOTE: The Supplied Storage Pins can only be used on Wrangler TJ models, or Cherokee XJ/ Grand Cherokee ZJ Models equipped with OE front skid plate. Important: Storage Pins must be mounted in a location that will allow FULL Suspension and steering travel without tire interference. TJ Models: Locate a mounting point for Storage Pins on the chassis that allows the disconnect to reach it without adjustment. Using a size F drill bit (0.275", the closest common size is 1/4"), drill a hole on the outboard side of each chassis rail and tap with 5/16-18 TPI Tap. Install storage pins using supplied 5/16 x 1-1/2" Allen Bolts. XJ/ZJ Models with OE Front Skid Plate: Locate the mounting point for storage pins on the OE Front Skid Plate that allows disconnect to reach it without adjustment. Drill a 5/16 hole in the outboard sides of skid plate. Install storage pins using supplied 5/16 x 1-1/2 Allen Bolts and 5/16 Nylock Nuts. XJ/ZJ Models without OE Front Skid Plate / Other Models: Do not install the supplied storage pins on the vehicle. Instead, the sway bar and quicker disconnects may be secured to chassis with plastic wire ties or bungee cords (not supplied.) *At this point installation is complete. Note that there will be leftover hardware and / or brackets regardless of the vehicle used for the installation. Retain these instructions and this leftover hardware if the Quicker Disconnects may be installed on a different Jeep model in the future. USE INSTRUCTIONS WARNING: Quicker Disconnects should ONLY be used during slow speed off-road situations. NEVER operate the vehicle on public roads or above 5 mph with the sway bar disconnected. Always verify that the disconnects have been re-attached to the vehicle prior to operating the vehicle at any speed above 5 mph. Operating a vehicle at speeds above 5 mph with the sway bar disconnected will cause vehicle instability and greatly increase the chances of loss of vehicle control. With the vehicle on flat, level ground, remove the spring-loaded quick pins. Remove the lower ends of the Quicker Disconnects from the bullet pins on the axle and secure them to the storage pins using the spring-loaded clamps. If the storage pins are not present, secure the Quicker Disconnects up and out of the way using plastic wire ties, a rope, or bungee cord. Verify that the bar will not interfere with the suspension as it moves through its travel cycle while disconnected. Once ready to return to the pavement, reconnect the Quicker Disconnects to the bullet pins and secure them with the spring-loaded quick pins. Note that if the vehicle is on unlevel ground, it will be difficult to attach / remove the Quicker Disconnects. If the Disconnects are difficult to remove even when the vehicle is perfectly level, it may be necessary to adjust the length of the links.

5 It is the owners responsibility to inspect all Rusty s products for proper torque specs to prevent loosening of components. Seat belts and shoulder harnesses should be worn at all times. Re-check all bolts and nuts after the first 300 miles and after any off-road usage during the first 300 miles. Although all of our products are made from the highest quality materials possible, they are not a substitute for Safe and Careful driving. In other words, have good safe on-road / off-road sense. Know the terrain, the speed limitations, and any obstacles that may lie ahead. Please remember to preserve our right to enjoy public land through the proper use of off-road vehicles. Thank you for choosing Rusty s Off Road Products.. For questions or suggestions, contact our Tech Department 7161 Steele Station Road Rainbow City, Al