Stabilizer Bar Disconnect Popping when ON (connected)

[andersman02]

I installed a badlands disconnect 2 years ago on my big bend. Since then, every time the body shifts (flexing the front suspension or turning hard/fast enough) I get a single "pop". If the body shifts back the other way, I get a "pop". This ONLY happens if the swaybar is engaged (limiting body roll). If i turn it ON (not limiting body roll) theres no "Pop". Heres more specifics:
-Ive tried replacing the end links
-Ive tried replacing the bushings and bolts
-Loosened and retorqued the end links AND mounting bushings numerous times
-HERES THE KICKER- It "pops" less and less the colder it it gets below 60 AND It DOES NOT "pop" when it's below freezing!!!!!!!! Weird!!!!
-I've put the OEM swaybar back on, no popping
-I have maybe .5" lift in the front if that from factory, I do have a aftermarket winch/bumper

I'm a mechanical guy who likes to know things, so this bothers me quite a bit that I can't figure it out.

Any ideas? Please no comments "just remove it" or "go back to the regular sway bar" Not going to do that.

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[PWillette]

Spit balling...I suspect it may have something to do with the difference in factory lift. The sway bar disco is set up for BL suspension which is an inch or two higher than Big Bend. Possible there are different end link part numbers (different lengths) between regular sway bar and auto sway bar disco? If the end link is too long or too short I could see it putting extra pressure on the auto sway bar disco.

 

[andersman02]

Spit balling...I suspect it may have something to do with the difference in factory lift. The sway bar disco is set up for BL suspension which is an inch or two higher than Big Bend. Possible there are different end link part numbers (different lengths) between regular sway bar and auto sway bar disco? If the end link is too long or too short I could see it putting extra pressure on the auto sway bar disco.

My train of thought too, I went through and looks like the ONLY different part number is the sway bar, the bushings and end links are the same.

They height difference could have something to do with it, but the badlands is only .5" I think shorter then Sasquatch, add my .5" over and Max is about 1" over badlands. Could definitely be though

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