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 Post subject: Quick dis connect sway bar link ideas
PostPosted: Thu May 17, 2018 6:43 am 
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I sleep in my van

Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
Hi,

After studying the Jeep Wrangler front quick disconnect front sway bar link, I did research and see that various kits are available for Jeeps.

On the Astro front sway bar is large diameter about 1 1/8" .
The idea of off roading with the sway bar disconnected is to let the front suspension have more articulation. But, off road speeds are slow, remember to re connect sway bar for safe use on the road at highway speeds.'

The Astro uses the typical sway bar end link that is like about a 6" bolt connecting the sway bar to the control arm with rubber isolation bushings.

The typical fast release set up uses a quick release pin to allow the link to be quickly dis connected with out wrenches.

A quick look around Pic n pull revealed some potential solutions.

1997 Ford Ranger front sway bar link is a good choice since it has eyes on both ends.'
On Astro remove links.
Then the next idea is to bolt U shape fittings to sway bar and to control arm.
Then the Eye to eye link is attached to the U fittings with 3/8" quick pins.

I will draw a sketch and take some photos.'

Also, the old 1993 Ford Exploer uses eye to eye links


AP


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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Thu May 17, 2018 1:22 pm 
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I sleep in my van

Joined: Wed Feb 01, 2012 8:10 pm
Posts: 436
Location: southeastern ct
the Zr2 guys had a QD kit for their swaybar disco's. I went to look up the link but the site is down.

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Captn. Crunch
"I don't beat my rig-I use it to it's maximum potential"
1994 Safari conversion (sold) and miss'n it!
1999 Safari SLE AWD
np236 transfer case
Torsen limited slip cast iron front diff
Torsen rear w/3.73's
2" body lift
S-10 rear leafs
Coming soon:
Skid plates
Rock rails


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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Thu May 17, 2018 4:46 pm 
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I sleep in my van

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Hi Captain,

Yes, I noticed that too. Anyway, I am convinced that we can design our own kit.

The 1997 Ford Ranger has nice cast aluminum links with eyes on both ends. The 1993 Ford Explorer has steel links eye to eye. Dimension: 3 7/8". Eye to eye centers,
Parts list
1. Ford eye to eye links qty 2
2. Uni strut P1973 u fittings qty 4
3. 3/8 X 3" quick pins qty 4 from mc master Carr this have nicer bail clip.
4. 1/2" nc grade 8 hex bolts

See sketch and photo in next post

AP


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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Thu May 17, 2018 4:54 pm 
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I sleep in my van

Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
Hi,

Astro sway bar dis connect design review:


Attachments:
File comment: Eye to eye link plus U fittings replace old link
image.jpeg
image.jpeg [ 1.25 MiB | Viewed 884 times ]
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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Thu May 17, 2018 4:57 pm 
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I sleep in my van

Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
Astro team,


Attachments:
File comment: 97 Ford ranger link is alloy; 93 Ford Explorer steel, both are 3 7/8" centers of eyes and have rubber insert in eyes
image.jpeg
image.jpeg [ 1.99 MiB | Viewed 884 times ]
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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Thu May 17, 2018 4:58 pm 
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Posts: 748
Parts list and sketch

AP


Attachments:
File comment: Parts list and assembly sketch
image.jpeg
image.jpeg [ 1.72 MiB | Viewed 884 times ]
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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Thu May 17, 2018 5:16 pm 
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I sleep in my van

Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
The eye needs 1 1/4" U.
The P1973 Uni strut U is 1 1/8"
May heat up U with Mapp gas or propane hand torch and spread the U fitting a bit.

The nice quick pins with good thumb release tang on bail are available at Mc Master Carr.''

The replacement Ford links with eye to eye could be available on A1Auto or RockAuto or Dorman, etc.

Hopefully we can get this design done. The idea would be to remove the end links and put in console cloth box when off roading. There is not much room on Astro control arm to just dis connect one end of link and bungee cord the link out of the way like they do on Jeeps.

AP


Attachments:
File comment: Astro has huge front OEM sway bar, about 1 1/8" OD which is good for highway safety of handling but more articulation and softer ride would be nice off road at slow speed
image.jpeg
image.jpeg [ 1.73 MiB | Viewed 884 times ]
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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Thu May 17, 2018 5:18 pm 
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Posts: 748
Sway bar dis connect photos

AP


Attachments:
File comment: Lower u fitting is Uni strut p1973
image.jpeg
image.jpeg [ 1.18 MiB | Viewed 884 times ]
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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Fri May 18, 2018 5:15 am 
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Posts: 748
Hi,

1AAuto has the Ford Ranger 1997 sway bar links. $45 per pair.

AP


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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Sat May 19, 2018 7:22 pm 
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Joined: Wed Nov 02, 2016 8:25 pm
Posts: 43
Been wondering about this myself, but as usual didn't get any further. Glad to see you working this out. Thanks!

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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Sun May 20, 2018 10:51 pm 
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Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
Hi All,

Did some additional bench test fitting.

The key thing is tat the Astro sway bar end link eye is located between the lower control arm and the upper control arm.

When the link is removed, a method must be found to keep the sway bar from moving from its normal location so the end eye of sway bar does not contact any metal.

So some sort of rubber or rubber hose could be looped thru the eye of the sway bar end and connected to the new Uni strut U fittings.

AP


Attachments:
File comment: The new total height is about 6.75". Which should fit since the old top grommet and washer and nut was about 6.5"
image.jpeg
image.jpeg [ 2.05 MiB | Viewed 847 times ]
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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Sun May 20, 2018 10:56 pm 
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I sleep in my van

Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
Hi,

I decided it is better to use the OEM M12 X 1.75 X 65 mm hex bolts and nuts to attach the Ford eye style link. A pin would rattle. And have a metal on metal issue .

When link is un bolted. The bolts and link are stored in glove box.

Then a rubber bungee or 1/4" rubber hose is looped thru eye of sway bar and the U fittings

AP


Attachments:
File comment: When dis connected, use rubber hose to tie sway bar end eye to U fittings
image.jpeg
image.jpeg [ 2 MiB | Viewed 847 times ]
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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Sun May 20, 2018 11:02 pm 
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I sleep in my van

Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
Hi,

The Jeep Wrangler sway bar is pulled up out of the way and secured.

On Astro there is no room to move the sway bar up and out of the way. Some method could be found to properly keep the sway bar end in the allowed region so it does not hit control arms during the articulation of the arms.

AP


Attachments:
File comment: End of sway bar must stay in its allowed region between upper and lower control arms and be constrained so it does not hit anything especially with increased articulation of suspension.
image.jpeg
image.jpeg [ 1.75 MiB | Viewed 847 times ]
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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Sat May 26, 2018 5:51 pm 
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I sleep in my van

Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
Hi,

Walker muffler rubber isolator #35706 $6.99 each looks promising for the rubber eye to eye to be inserted when metal link is disconnected.

AP


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 Post subject: Re: Quick dis connect sway bar link ideas
PostPosted: Mon May 28, 2018 7:34 pm 
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I sleep in my van

Joined: Sun Jan 13, 2008 5:23 am
Posts: 748
Hi,

I also have the Hellwig rear sway bar on my 2003 AWD Astro.
It has much more room near- the end links to incorporate the quick dis connect feature.
I will spend some time working on a design idea for rear sway bar dis connect.

AP


Attachments:
File comment: Rear Hellwig sway bar could get dis connect type link
image.jpeg
image.jpeg [ 2.11 MiB | Viewed 775 times ]
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