E-Disco Conversion To Manual - JKowners.com : Jeep Wrangler JK Forum
 
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post #1 of 21 Old 01-28-2011, 10:20 PM Thread Starter
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E-Disco Conversion To Manual

Here are some pics of how the conversion to manual control was done.
Go here to review how it works in its stock configuration:
https://www.jkowners.com/forum/showthread.php?t=41373












Last edited by ronjenx; 01-28-2011 at 10:32 PM.
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post #2 of 21 Old 01-28-2011, 10:21 PM Thread Starter
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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.

[IMG][/IMG]

Last edited by ronjenx; 11-11-2018 at 03:52 PM.
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post #3 of 21 Old 01-28-2011, 11:24 PM
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Waiting to see how all this looks. Great job man.

I really don't want to go with the quick disconnect route when my fails, we all know it is only a matter of time. I really like this idea and want to see how you hook it up in the cab
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post #4 of 21 Old 01-29-2011, 05:32 AM
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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.

07 Rubi rescue Green
"The previous explanation is based on my historically bad memory of a conglomeration of past experiences and conversations. The opinions above probably have some kernel of truth to them but the details are most likely flawed on some level. Please acquire further help from experts before listening to anything I say."
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post #5 of 21 Old 01-29-2011, 07:56 AM
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Nice job.

Usually the motor works fine. Its the board that gets screwed up. You can bypass all the electronics and just use the electric motor with a simple switch:

https://jkowners.com/forum/showthread.php?t=14449

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post #6 of 21 Old 03-24-2011, 07:28 PM Thread Starter
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See post # 2 for a clip of the lever in action. Let me know if the lighting is adequate, and how it plays.

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post #7 of 21 Old 03-24-2011, 08:37 PM
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Quote:
Originally Posted by ronjenx View Post
See post # 2 for a clip of the lever in action. Let me know if the lighting is adequate, and how it plays.
I see what you did there and I like it

Vid looks fine too. Would like to see some close ups of the action though.

Been keeping an eye out for action in this thread. Looking forward to seeing when you actually put it in the rig and get some real world testing done.

Great work ron.
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post #8 of 21 Old 05-26-2011, 03:38 AM
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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..)
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post #9 of 21 Old 05-26-2011, 04:35 AM Thread Starter
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Originally Posted by donvillejeep View Post
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..)
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.
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post #10 of 21 Old 05-26-2011, 08:26 AM
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excellent mod

Quote:
Originally Posted by ronjenx View Post
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.
i picked up a throttle idle cable for a tractor trailer. i think it maybe a little over kill though. $40 i think a long bicycle brake cable and a shifter lever should be good enough. what do you think?
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post #11 of 21 Old 05-26-2011, 10:24 AM Thread Starter
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Quote:
Originally Posted by donvillejeep View Post
i picked up a throttle idle cable for a tractor trailer. i think it maybe a little over kill though. $40 i think a long bicycle brake cable and a shifter lever should be good enough. what do you think?
Try it to see if it is strong enough. I had trouble with automotive cables failing due to the tension required to compress the spring.
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post #12 of 21 Old 05-26-2011, 03:05 PM
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Off topic but is the edisco covered under the powertrain warranty?


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post #13 of 21 Old 05-26-2011, 03:39 PM Thread Starter
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Off topic but is the edisco covered under the powertrain warranty?
No, it is not.
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post #14 of 21 Old 06-02-2011, 06:58 PM
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twist-on / twist off

Just saw on facebook that EVO MFG is looking to put out a twist-on / twist off feature for the E-disco. looks pretty simple.

Rubicon Unlimited
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post #15 of 21 Old 06-03-2011, 06:49 AM Thread Starter
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Quote:
Originally Posted by drcre8tive View Post
Just saw on facebook that EVO MFG is looking to put out a twist-on / twist off feature for the E-disco. looks pretty simple.
Can you describe it a little more, or post a link to it?
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post #16 of 21 Old 06-07-2011, 06:54 PM
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Offroad Evolution just released their EVO NoLimits Manual Rubicon Swaybar Disconnect. Looks interesting and price seems ok.
I might give them a try.


http://offroadevolution.com/store/pr...d=EVO-NOLIMITS

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post #17 of 21 Old 06-07-2011, 07:09 PM Thread Starter
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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.
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post #18 of 21 Old 03-11-2012, 04:10 PM
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I know that this is probably already out there and is a little off topic bot how do you get the light to stop flasing on the dash once you have completely removed the E-disco and gone with a Currie RJ?
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post #19 of 21 Old 03-11-2012, 04:28 PM
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Quote:
Originally Posted by JK-JAKE View Post
I know that this is probably already out there and is a little off topic bot how do you get the light to stop flasing on the dash once you have completely removed the E-disco and gone with a Currie RJ?
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post #20 of 21 Old 08-21-2012, 04:13 PM
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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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post #21 of 21 Old 08-22-2012, 09:24 AM
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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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