Rubicon swaybar complete disassembly

[Colonelmustard81]

Hi Folks,
I am working on a Rubicon swaybar and was wondering if anyone has done a complete disassembly of one?

It had a substantial amount of corrosion inside and I want to completely disassemble, maybe replace the seals on the housing around the swaybar, powdercoat the bar again, etc. On the main side I can see a gear which seems to be pressed onto the bar (which is splined) and there is a bronze bushing in the housing that runs on the lower part of that, but it is putting up a fight when I try to pull it off the splined section. Anyone done this? Thanks.

[NTRubicon]

I have disassembled, cleaned and re-greased mine a few times now. Its a surprisingly simple device with very little serviceability. The main seal around the housing can be as watertight as you want it to be, but there are other avenues for water to get into the mechanism.

The main gear is pressed in and likely if it disassembled I would suspect it would be very difficult to get it back together. 3 removable parts I dealt with - opposing gear, bracket that holds opposing gear, 1x spring.

Keep the actuator clean, make sure everything has some decent marine grease on it, and I find it runs just fine. I have serviced it 3 times in 6 years. Now I think of it, It's probably due for a look soon.

[Colonelmustard81]

I basically came to the same conclusion regarding pulling the gears off the bar halves, they might not go back on. The housing halves and bar halves were acting as a sold piece (ie stuck to each other). I have managed to get them freed up and the dog gear and fork cleaned up and all operating (some nasty pitting, but all functional).

I think I'll leave well enough alone at this point rather than create more issues trying to disassemble any further.

The electronics are toast so I'll be converting to pneumatic from EVO or TTO.

[NTRubicon]

DBOR has a manual system like the EVO one as well if you're looking for local supply