Off Road Only SwayLOC Anti-Sway Bar System


How to Operate the Off Road Only SwayLOC Anti-Sway Bar System 1. The air cylinder can open the latch with as little as 20 psi air pressure if the axle is not loading the latch. The recommended procedure to disconnect SwayLOC is to flip the switch as you are coming to a stop, and then as the movement from the axle loads and unloads the latch, it will unlatch as soon as the load is light enough. 100 to 150psi should allow immediate unlatching if sitting on level ground and provided the links were adjusted properly during install. 2. When you start driving on the road, simply turning the switch off will result in the air cylinder pulling the latch back into place once the arms pass over the keyed opening. This may take just a bit of driving on flat ground so please use caution on quick maneuvering until you are sure that the latch has engaged. 3. After completing a test drive, check the torque of all mechanical and electrical connections on the SwayLOC. After a month of driving, and then at each vehicle service interval, check all fasteners to ensure that they remain tight, especially the 3/8 bolts that tighten the arms to the torsion bars. Maintaining Your New Off Road Only SwayLOC Anti-Sway Bar System Periodic disengagement/re-engagment is recommended to keep all parts moving, and an occasional shot of WD40 or other spray lubricant on the air cylinder shaft may prevent sticking of the latch assembly. Additional Photos




Off Road Only SwayLOC Post Installation Notes For those of you who are not aware, the Off Road Only SwayLOC Anti-Sway Bar System on this write-up is Generation 2 design. Compared to the Generation 1 design, the new SwayLOC system comes ecoated black for corrosion resistance. Also, the two torsion bars no longer have a bushing on the wearing surface as the tolerances were tightened up with a new and thicker bar design. Last but not least, the air cylinder has been redesigned with a vent port that a closed nylon air line gets plugged into which allows movement but prevents dirt, mud, moisture from getting into the cylinder. As with all the Off Road Only products I've purchased and use, the quality of the SwayLOC system is top notch. The welds are beautiful, the ecoating seems durable and a lot of attention has been put into the details. Installation is easy and can be done by yourself using basic tools and I would highly recommend this anti-sway bar system.
Trail Tested 10/12/05

I just got a chance to test out my new Off Road Only SwayLOC for the first time today and I must say I was really impressed at how well it works. Granted, I had always been please with the ride and stability the SwayLOC provided around town but it was the significant stability on the trail that really amazed me. Truly, the SwayLOC is more than just a fancy swaybar system and definetly a huge step up from just disconnecting your sway bar links. Need I say, I would highly recommend buying and installing one on your Jeep!!

Off Road Only SwayLOC
Dual Rate Anti-Sway Bar System

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	30. Back at your work bench, begin assembling your ORO SwayLOC links by installing a jam nut on to each of the rod-ends.
	31. Install the ORO SwayLOC rod-ends onto the hex aluminum housings provided with the kit.
	32. Adjust the overall length of each links so that the ORO SwayLOC arms will not limit the extension of the front suspension at a droop or come into contact with the fender area at a full compression. Measure the gap between your bump stops and the lower spring perch to determine the approximate up travel your ORO SwayLOC arms will make. Be sure to account for the compression of the rubber stop too. Once this has been done, fasten your links using a 3/4" and 19mm wrench.
	33. Using a 5/8" and 3/4" wrench, attach the assembled links on to the outside of the ORO SwayLOC arms and secure them in place using the nylock nuts provided with the kit. If your jeep has wheels with more than 4" of backspacing, you may need to install the passenger side link on the inside of the ORO SwayLOC arm.
	34. Again, using a 5/8" and 3/4" wrench, attach the ORO SwayLOC links to the inside of the sway bar mounts on your Jeep's axle and then secure them in place using the nylock nuts provided with the kit.
	35. Back at your workbench, open the package containing the ORO SwayLOC air solenoid and install the mounting bracket onto it using the self-tapping bolts provided. You will need a 1/4" socket for this job.
	36. Using the ORO SwayLOC air solenoid bracket as a template, locate and mark a place under the hood of your jeep where you will mount it. I decided to use the metal bracket on the driver side where a cruise control unit would normally be mounted. Since this location already has holes in it, I only needed to drill one new hole.
	37. Mark the location of where your hole needs to be drilled using a center punch.
	38. Drill your bracket mounting hole using a 5/32" metal drilling bit.
	39. Install your ORO SwayLOC air solenoid onto the bracket using the bolts and spoked nuts provided with the kit. You will need a small flat head screwdriver to secure the bolts in place.
	40. If you look under the dash on the driver side of your Jeep, you should see a large rubber plug on the firewall above the gas pedal and towards the center console. Drill a small 1/4" hole through this plug. As you can see in this photo, I already have a cable for my hand throttle going through it.
	41. The ORO SwayLOC air solenoid should have come with a separate two prong connector that has a white and black wire with a ring on the end of it. Feed the white wire through the hole you just drilled in the rubber plug on your firewall. Then, inject the hole with a little silicon sealer to close it off.
	42. Attach the black wire with the ring connector to your Jeep's frame or body. I attached mine to a rocker guard bolt on the body of my Jeep.
	43. Plug the ORO SwayLOC air solenoid wiring harness into the two prong connector and then zip-tie the wires up against the firewall.
	44. Climb back into your Jeep and remove the rubber transmission shifter boot by carefully pushing in the sides and lifting up. With a little effort, it should pop out without the assistance of tools.
	45. Route the white wire you fed into the cab of your Jeep under the center console. Then drill a 3/4" hole into your console or wherever you want to install the ORO SwayLOC switch. I would recommend using a unibit for this job as it will drill a very clean and accurate hole.
	46. Take the red ORO SwayLOC activator switch and feed the red power and black ground wire through the hole you just drilled. Feed the white wire coming from the air solenoid up through the hole and plug it into the center prong on the switch.
	47. Snap the red ORO SwayLOC activator switch into place and then feed the power and ground wires through the center console towards the firewall. Reinstall the transmission shifter boot back onto the center console.
	48. Remove your glove box to gain access to the fuse box. The ORO SwayLOC should come with a fuse tap so that you can piggy back the fused side of a 10 amp fuse but if your Jeep comes equipped with an auxiliary switched power lead, you can attach your ORO SwayLOC power wire directly to it. The ORO SwayLOC air solenoid draws less than 300ma.
	49. Lift up the carpeting on the passenger side of your Jeep and route the ORO SwayLOC activator switch wires underneath it. Then, attach the ground wire to a bolt on your tub that will provide a good ground.
	50. Take the longer 1/4" nylon air line and insert one end of it into the push-in fitting on your SwayLOC air cylinder closest to your front bumper.
	51. Take the shorter 1/4" nylon air line that has one of the ends melted closed and insert the open end into the push-in fitting on your ORO SwayLOC air cylinder closest to the latch. Keep the length of air line whole and Leave the melted end intact. This air line will allow the air cylinder to move but keep dirt, mud, moisture from getting into it.
	52. Make sure to leave a service loop on both air lines to allow for adequate movement and then secure them in place with a zip tie.
	53. Route both air lines across your Jeep's front grill using zip ties to hold it in place. The shorter air line should stop here but continue to route the longer hose along your Jeep's frame rail and up into the engine compartment where your ORO SwayLOC air solenoid is located.
	54. Cut the 1/4" nylon air line and insert it into the push-in fitting labeled "OUT" on your ORO SwayLOC air solenoid. This fitting should be located next to the wiring harness. If you have on-board air, insert the remaining air line into the push-in fitting labeled "IN" and then route it to an air manifold connected to your compressor.
	55. If you do not have on-board air and purchased the optional air tank with your Off Road Only SwayLOC Anti-Sway Bar system, you will need to begin assembling it now. Go back to your workbench, apply some teflon tape to the brass reducers and install them onto the tank using an 11/16" wrench.
	56. Install the 1/4" NPTs to the 1/4" tube fitting using a 9/16" wrench. The optional tank should only have one of these and your ORO SwayLOC kit should have come with the other one you need.
	57. Climb under your Jeep from the driver side and hold your air tank up to the tub, parallel to the length of the Jeep and just behind where the driver seat would be. Use the air tank as a template and mark off where you will be installing it and where you will need to drill the mounting holes.
	58. Make sure the carpeting inside your Jeep has been pulled out of the way along with anything else that might be on the floor of your Jeep. Then proceed to drill the air tank mounting holes using a 3/8" metal drilling bit.
	59. Inside the cab of your Jeep, take your 5/16-18x1 stainless steel bolts, slip a washer on them and insert them into the holes you just drilled. Place a pair of vice-grips and clamp it onto one of the bolt heads.
	60. Back underneath your Jeep, secure the bolt that is clamped with a nylock nut. You will need a 1/2" wrench for this job.
	61. Insert the remaining 1/4" nylon air line into the push-in fitting pointing towards the front of your Jeep and route it along the driver side frame rail toward the engine where the ORO SwayLOC air solenoid is located.
	62. Cut the 1/4" nylon air line and insert it into the ORO SwayLOC air solenoid push-in fitting labled "IN". Also, be sure to install the muffler on to the exhaust port of the air solenoid.
	63. Using a piece of 1"x1/8" stainless steel bar stock, I made a bracket that I could attach the schrader valve to and mount it to my Jeep's driver side frame rail using an existing bolt (previously used for a side step).
	64. Take the remaining 1/4" nylon air line, insert it into the air tank's rear push-in fitting and then route it to your schrader valve's push-in fitting.
	65. Air up your air tank using any air source and your Off Road Only SwayLOC Anti-Sway Bar System is ready to use. To operate it, simply turn on the activator switch you installed inside your Jeep and go.
That should be it. Your Off Road Only SwayLOC Anti-Sway Bar System installation is now complete. Please let me know if you have any questions.

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