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E-Disco Conversion To Manual

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36K views 20 replies 12 participants last post by  JeepUpKeep37s  
#1 · (Edited)
#2 · (Edited)
Here is a clip of the progress on the lever.
It's a mock-up using an XJ console I had in the barn. I won't be installing the sway bar/lever into my JK until the electronic one fails.

The piece of track hanging from the bar simulates the bar being loaded from the Jeep being on uneven ground. As the Jeep moves, the bar will unload, and release. The lever will remain in the release position from being over-center.
When moved to the reconnect position, the lever will be free until the splines on the bar line up. It will be obvious when the bar reconnects, as the lever will be held in the forward position.
Watch the lever as the bar reconnects. You will see it move forward.

Image
 
#4 ·
I guess it's time to dig out my broken e-disco.
The only problem is that my memory is so bad latley that I don't know where to look for it.
 
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#5 · (Edited)
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D
#8 ·
great job i was wondering what kind of cable did you use? also. in one of your pics. i see you kept the plastic stub on the end that the cable ataches to. is there a purpose for that piece? or could you of just fastened the cable to the actual fork? (piece of plastic that has the spring that the motor pushes on..)
 
#9 ·
The piece is retained because it includes the spring, which allows the cable to complete it travel, even if the sway bar is loaded to the point it won't disconnect. Once the bar is unloaded, the spring will move the shift fork.
Otherwise the operator would have to keep pulling on the lever until the fork moves.

The cable is a throttle push-pull cable from Aircraft Spruce.
 
#16 ·
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#17 ·
That is very nice, and simple. Like you said, the price isn't bad.
I have to admit, I may have gone this route if I hadn't done mine yet.

Something like that crossed my mind when I was modifying mine.
I decided to keep it actuated from the cab, though.
 
#20 ·
procal is the only one that will do it? not a superchips or hypertech or any other brand? and can't you also get the dealer to turn it off for you? (obviously it'd have to be a cool dealer, but still...)
 
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#21 ·
I love the cable idea. The problem I see with EVO unit is access into the area to turn it with my current bumper and winch in the way. plus gettting dirty after a day of offroad. cable better than a motor IMO. but its just my opinion... a cable can rust and sieze to...LOL

My swaybar is currently locked and the light is flashing. I cannot unlock. any hope for me to fix this thing.

my plan is to take it apart. if I cant resolve it then I plan on leaving the motor and electronics off of it and just silicone a cover onto it to keep stuff out until I find the setup I am willing to go with.
Your input on possible trouble shooting the factory crap will be helpful or links. searching this topic is hard as titles are off the wall making a logical search tougher so I may miss a thread on this. so links that you know of will be helpful.

thanks for posting this kind of info up.

Wes.
 
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