VANCOMPASS 1061-2015 Front Sway Bar Disconnect Kit Instruction Manual

VANCOMPASS 1061-2015 Front Sway Bar Disconnect Kit

Specifications

• Product Name: MERCEDES SPRINTER 4X4 / AWD, FRONT SWAY BAR DISCONNECT
• Compatibility: Fits MERCEDES SPRINTER 4X4 / AWD models
• Parts Included: See Parts List below
• Tools Needed: Torque wrench, basic wrench and socket set, pneumatic die grinder or HD Dremel-style tool
• Service Interval: Once a year or every 15k miles

Installation Instructions

1. Note: Ensure proper vehicle support based on model year.
2. Begin by removing the driver-side tyre on applicable models.
3. Clearance the lower control arm sway bar tab bracketry using a die grinder.
4. Check for proper fitment and clearance without damaging CV boot.
5. Install sway bar disconnect studs with blue Loctite and washers.
6. Install sway bar disconnect components as per instructions.
7. Secure with lynch pins and re-check all bolt torques after driving 100 miles.

Service Instructions

1. Once a year or every 15k miles, remove and grease the sway bar disconnect.
2. Use a 5.5mm allen wrench to disassemble and reassemble the sway bar disconnect.
3. Torque the flat head socket cap screws to 20-25 ft-lbs (27-34 N.m).

FAQ

• Q: How often should I check the bolt torques after installation?
• A: Re-check all bolt torques after driving 100 miles and periodically as part of regular maintenance.
• Q: Can I install this kit on a 2023+ AWD van without raising it?
• A: Yes, on 2023+ AWD vans, this kit can be installed with the vehicle sitting under its weight at ride height.
• Q: What is the recommended tool for grinding the lower control arm bracketry?
• A: Use a pneumatic die grinder or HD Dremel-style tool for metal grinding as mentioned in the tools needed section.

General Notes

• For the most up-to-date and current instructions, please visit our website at www.vancompass.com
• Please read all instructions thoroughly before starting to install Van Compass products.
• This suspension kit can be completely removed, allowing the vehicle to be returned to stock configuration if desired.
• Note this is a simple bolt-on sway bar link on 2023+ AWD models. 2015-2022 4×4 vans will require the use of a die grinder and included burr bit to clear a piece of the OEM suspension bracketry for proper fitment. See steps 4-6 for details.
• This sway bar disconnect is designed to allow the operator to easily disconnect the front sway bar of the van when travelling offroad to allow the front suspension to be more compliant and use its full range of motion to mitigate the 3-wheeling / tripod effect Sprinters are known for.

Parts List

1061 – 2015-PRESENT, MERCEDES SPRINTER 4X4 / AWD, FRONT SWAY BAR DISCONNECT KIT

• (1) 106103 MERCEDES SPRINTER 4X4 / AWD, FRONT SWAY BAR DISCONNECT
• (2) 106101 MERCEDES SPRINTER 4X4 / AWD, FRONT SWAY BAR DISCONNECT STUD
• (2) BM12-1.75-30-10.9 M12-1.75 X 30MM LONG, BUTTON HEAD SCREW, CLEAR ZINC
• (2) WF-M12 FLAT WASHER, M12
• (2) LP-.188-1250 3/16” LYNCH PIN X 1.250” LONG
• (1) BB-375-250 3/8” DIAMETER, ¼” SHANK, 2.50” LONG BURR BIT
• (1) SB-DC-BAG SWAY BAR DISCONNECT STORAGE BAG
• (1) LTBL-02 BLUE LOCTITE, 2 ML TUBE

Tools Needed

• Quality Jack and 2 jack stands.
• Simple hand tools:
  • Torque wrench.
  • Basic wrench and socket set:
• Metric sizes: 18mm
• T-40 Torx Bit
• 5.5mm, 8mm allen wrench
• Small punch or screwdriver
• For 2015-2022 4×4 models only:
  • Pneumatic die grinder or HD Dremel style tool for metal grinding.
  • Approximate Installation Time
• 1-2 hrs.

Installation

1. Note, on 2023+ AWD vans, this kit can be installed with the vehicle sitting under its weight at ride height. Simply turn the wheel to full driver lock to gain clearance to the driver-side front sway bar link.
2. On 2015-2022 4×4 models, begin by safely supporting the front of the vehicle so that the front suspension can hang free.
   • Remove the driver-side tire.
3. Remove the driver-side sway bar link. Use an 18mm wrench to hold the nut and spin the tie rod end loose with a T-40 torx bit on a ratchet. Do this for both the upper and lower tie rod end of the sway bar end link.
   • Note, that an air or electric ratchet fitted to the Torx bit speeds up this process significantly.
   • Note, there can be some tension on the sway bar link making the sway bar link more challenging to remove. If needed, use a pry bar as shown in the image below to alleviate tension on the link for easier removal.
4. Note; steps 5-6 are for 2015-2022 4×4 models only. 2023+ AWD models, skip ahead to step 7
5. A small portion of the lower control arm sway bar tab bracketry must be ground away for clearance of the new sway bar disconnect. See the images below of the area to be cleared.
   • Use the included 3/8” diameter burr bit to clear the bracket. Before & after photos shown.
6. Be careful to not contact/damage the CV boot during grinding. Test fit the lower disconnect pin & fit the sway bar link to ensure there is no contact with the link to the bracket.
   • Once satisfied with the clearance/fitment. Touch up any exposed areas of metal with quality spray paint to prevent corrosion.
7. Install the sway bar disconnect studs as shown in the image below. Utilize an 8mm allen wrench to tighten the button head bolts. Be sure to use an M12 flat washer under the bolt head and put a dab of blue Loctite on the threads of the bolts.
   • Keep the stud from spinning by using a small screwdriver or punch through the lynch pinhole.
8. Fitting a torque wrench can be difficult here, snug the bolt down till it is bottomed and give the bolt an additional ¼ to ½ turn. Torque spec should be about 55 ft-lbs. (74 N.m) for reference.
   • Orient the lynchpin mounting holes horizontally with the ground for ease of use and clearance with the front axle shaft.
9. Install the sway bar disconnect. Install the short bend length first at the control arm disconnect pin. The long length goes up towards the sway bar itself.
   • Note, if installing the sway bar disconnect with the suspension at droop, it will be helpful to pry the sway bar up / down for proper alignment of the upper disconnect pin.
10. Install lynch pins. The completed installation is shown below.
11. Re-check all bolt torques after 100 miles of driving.

Installation is Complete

Directions for use

1. Remove the sway bar disconnect for any duration of off-road driving. Both high-speed and low speed off road travel will benefit from the added compliance provided by disconnecting the front sway bar.
2. Removal and installation of the sway bar link is best done when the van is on a flat, level surface and the suspension is not articulated. Turn the steering wheel to full driver lock for more room to remove/install the sway bar disconnect.
3. Use the included storage bag to store the sway bar disconnect and associated hardware when removed from the vehicle.

Service Interval / Instructions

1. Once a year or every 15k miles, remove and grease the sway bar disconnect.
2. Use a 5.5mm allen wrench to remove the two flat-head socket cap screws and separate the two halves of the sway bar disconnect.
3. Thoroughly clean all the components. Re-grease the bushings as described below with a quality chassis grease such as Lucas Red N Tacky #2 grease.
   • Fill the centre rib and horizontal voids of the bushing with grease as shown. No need to overdo it, just a ¼” wide film that fills the voids of the bushing will suffice.
4. Re-assemble the sway bar disconnect. Torque the flat head socket cap screws to 20-25 ft-lbs (27-34 N.m)
5. Re-install on vehicle

RELEASE OF LIABILITY

I, the customer, do hereby release and forever discharge Van Compass LLC their agents, employees, successors and assigns, and their respective heirs, personal representatives, affiliates, successors and assigns, and any and all persons, firms or corporations liable or who might be claimed to be liable, whether or not herein named, from any and all claims, demands, damages, actions, causes of action or suits of any kind or nature whatsoever, whether known or unknown, fixed or contingent, which I now have or may hereafter have or claim to have, as a result of or in any way relating to the following: Parts sold & installed by Van Compass LLC or parts sold & installed by end- user; any parts sold online, any parts sold online or installed by a re- seller, any parts installed by an installation shop. It is understood and agreed that this payment is made and received in full and complete settlement and satisfaction of the aforesaid actions, causes of action, claims and demands; that this Release contains the entire agreement between the parties; and that the terms of this Agreement are contractual and not merely a recital. Furthermore, this Release shall be binding upon the undersigned, and his respective heirs, executors, administrators, personal representatives, successors and assigns. This Release shall be subject to and governed by the laws of the State of Idaho.

PRODUCT SAFETY WARNING

Van Compass LLC strongly recommends the installation of products be done by a certified mechanic. If this does not occur, be certain the person(s) installing the product read, understand and follow all instructions and warnings about the application before installation. Do not add, alter, or fabricate any factory or aftermarket parts to increase vehicle height over the intended height of the Van Compass LLC product purchased. Mixing component brands is not recommended.
Installation of suspension lift kits or any other lifting kits or devices will raise the centre of gravity. For this reason, Van Compass LLC urges that extreme caution be used when encountering driving conditions that may cause vehicle imbalance. Furthermore, the driver’s field of vision and judgment will not be as good due to the height of the vehicle. Due to the installation of larger tyres, the speedometer will read slower than the actual speed being traveled and more distance will be required to stop the vehicle. It is the owner’s responsibility to caution and warn any potential driver of the vehicle about these driving and handling conditions. Van Compass LLC will not be held liable or responsible for damages or personal injuries resulting from the use of lifting devices and or related products. The tyres and rims should be changed to sufficiently increase the vehicle’s total overall width and stability to help accommodate lifting devices.
Van Compass LLC aftermarket suspension products and accessories modify a vehicle for uses that exceed conditions anticipated by the vehicle manufacturer. The uses include the high-performance demands required during off-road. These conditions vary in the degree of extremity and cannot be controlled by the vehicle or product manufacturer. If the components within the suspension system or accessories become worn due to frequent and/or extreme use, the safety and reliability of the vehicle is at risk. The maintenance of aftermarket equipment to ensure the vehicle occupant’s safety is entirely your responsibility. Do not purchase Van Compass LLC products unless you are willing to accept this responsibility. Do not install any Van Compass LLC suspension products or accessories unless you feel competent at installing the product without causing present or future injury to yourself or other vehicle occupants; seek an authorized installation centre.
Most states have some type of law limiting vehicle height. The amount of lift allowed, and how the lift can be achieved, varies greatly. Several states offer exemptions for farm and commercial registered vehicles. It is the vehicle owner’s responsibility to check state and local laws to ensure that their vehicle will comply. Van Compass LLC reserves the right to make changes in design, materials and specifications as deemed necessary without prior notice and without assuming the obligation to modify any product previously manufactured. Obligations or liabilities will not be assumed to similar products previously advertised.

This Release of Liability and Product Safety Warning has been read and fully understood by the undersigned and has been explained to me.

References

• Van Compass
• Van Compass

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