Installation instructions for Rubicon Express JK
Contents
1. 1387 REAR UPPER BUMP STOPS 2 86 RM22016 REAR BUMPSTOP PAD 1 10319 HARDWARE PACK REAR BUMPSTOP 4 3 8 16 3 4 GR 8 HEX BOLT 4 3 8 GR C NYLOCK NUT RE2001 FRONT SHOCK RELOCATORS HWC15013 HARDWARE PACK FRONT SHOCK 86 RM24063 SHOCK RELOCATION BRACKET DRVR 86 RM24064 SHOCK RELOCATION BRACKET PASS 35 RM31024 BRACKET SPACER 1 X 1 2 X 11 2 HWC15014 HARDWARE PACK FRONT SHOCK 1 2 X 4 1 2 HEX BOLT GR 8 Pe 2 1 2 STOVER NUT GR 4 1 2 HARDENED FLAT WASHER 3 3 8 X 1 HEX BOLT GR 8 3 3 8 STOVER NUT GR C 6 3 8 HARDENED FLAT WASHER 2 1 4 20 X 1 HEX BOLT GR 8 2 1 4 20 STOVER NUT GR 4 1 4 20 HARDENED FLAT WASHER 1 HWC15015 HARDWARE PACK ZIP TIES RE1609 REAR TRACK BAR BRACKET 1 86 RM24057 REAR TRACK BAR RELOCATION BRKT 1 HWC15019 HARDWARE PACK CAM KIT 2 35 RM24074 CAM BLOCK OFF PLATE 1 9 16 X 3 HEX BOLT GR 8 1 9 16 USS GR 8 STOVER 1 9 16 SAE GR 8 FLAT 1 35 RM62010 U BOLT 1 HWC15020 HARDWARE PACK TRACK BAR BRKT 1 9 16 X 3 1 4 GR 8 HEX BOLT 1 9 16 GR C STOVER NUT 2 9 16 SAE FLAT WASHER 2 3 8 X 1 GR 8 HEX BOLT 2 3 8 GR C STOVER NUT 4 3 8 SAE FLAT WASHER 1 35 RM31022 TRACK BAR SPACER 2 1 2 SAE STOVER NUT 2 1 2 SAE FLAT WASHER RE1157 REAR SWAY BAR END LINKS 4 RM40010 HOURGLASS BUSHING 2 35 RM11065 REAR SWAY BAR END LINK 4 51792 SLEEVE 5 8 X 1 2 X 1 37 1 HWC15025 HAR2. flash the computer to adjust for proper tire size and ESP control settings Revised 4 15 14 TROUBLESHOOTING Rear driveline Acceleration vibration Caused by the pinion being too high in relation to the transfer case output shaft Adjust up per control arm to lower pinion accordingly Deceleration vibration Caused by the pinion being too low in relation to the transfer case output shaft Adjust upper control arm to raise pinion accordingly High speed wobble It is a condition where front tires will shimmy after hitting a bump Avoid bias ply tires and wheels with excessive offset Check for worn or loose parts most cases a reduction of positive castor will eliminate this condition Revised 4 15 14 CON EXPRESS ADVANTAGE LI FETI ME WARRANTY Notice to Owner Operator Dealer and Installer Vehicles that have been enhanced for off road performance often have unique handling characteristics due to the higher center of gravity and larger tires This vehicle may handle react and stop differently than many passenger cars or unmodified vehicles both on and off road You must drive your vehicle Safely Extreme care should always be taken to prevent vehicle rollover loss of control which can result in serious injury or even death Always avoid sudden sharp turns or abrupt maneuvers and allow more time and distance for braking Rubicon Express reminds you to fasten your seat belts at all times and red
3. 9 16 12 STOVER NUT GR 8 9 16 SAE WASHER GR 8 RE4544 FRONT 4 LI NK LOWER ARM 2 88 RM31012 FRONT LOWER CONTROL ARM 2 HWC15024 HARDWARE PACK FRONT LOWER ARMS 2 9 16 12 X 4 HEX BOLT GR 8 4 9 16 SAE FLAT WASHER 2 9 16 12 STOVER NUT GR RE4526 REAR 4 NK ARM BRACKETS 3 35 RM24028 NUT PLATE 2 86 RM24143 4 LINK DUAL NUT PLATE 1 86 RM24135 4 LINK REAR FRAME BRACKET DRVR 1 86 RM24138 4 LINK REAR FRAME BRACKET PASS 1 HWC15028 HARDWARE PACK 4 LINK BRACKET 5 1 2 13 X 1 1 2 HEX BOLT GR 8 5 1 2 SAE HARDENED FLAT WASHER 2 9 16 12 X 4 HEX BOLT GR 8 2 9 16 SAE HARDENED FLAT WASHER RE4547 REAR 4 LI NK UPPER ARMS 2 88 RM31123 4 LINK REAR UPPER CONTROL ARMS RE4546 REAR 4 LI LOWER ARM 2 88 RM31015 4 LINK REAR LOWER CONTROL ARM 001 BOX 1 RE1143 FRONT SWAY BAR DISCONNECTS RM11195 FRONT GEN 2 SWAY BAR END LINK RM40010 GEN 2 HOURGLASS BUSHING RM10090 REDUCER SLEEVE RM11200 GEN 2 STOW AWAY BRACKET RM11205 GEN 2 ALUMINUM STOW AWAY PIN RM11140 STEEL PIN RM11155 GEN 2 MISALIGNMENT SPACER RM20815 SWAY BAR AXLE MOUNT TAB DRVR RM20816 SWAY BAR AXLE MOUNT TAB PASS QAI1CFR8 1 2 RH STAINLESS FEMALE ROD END HWC12005 GEN 2 RETAINER PIN 1 2 13 X 1 1 2 GR 8 BOLT 1 2 13 X 2 1 2 GR 8 BOLT 1 2 20 GEN 2 JAM NUT 1 2 13 NYLOCK NUT 1 2 USS FLAT WASHER 12 1 75 X 35 HEX BOLT M12 USS FLAT WASHER M12 LOCK WASHER
4. OE hardware Photo 30 Torque the 1 2 hardware to 35 105 Photo 30 Step 14 Rear Shock Installation A Install your new rear shocks into the original mounting positions using the previously removed OE hardware Torque the upper mounting hardware to 20 105 and the lower to 35 ft lbs Photo 31 Photo 31 Revised 4 15 14 Step 15 Final Details and Adjustments A NOTE NOTE Install the front transfer case yoke RE1810 and front driveshaft RE1883 365 or RE1883 385 2012 and up automatic trans into the vehicle using the previously removed OE hardware See enclosed driveshaft and flange adapter kit instruction manuals for reinstallation Install the rear driveshaft flange adapter RE1805 and rear driveshaft RE1887 430 4 DOOR OR RE1883 240 2 DOOR into the vehicle using the previously removed OE hardware See enclosed driveshaft and flange adapter kit instruction manuals for reinstallation On both sides of the vehicle check the routing of the brake lines and the ABS wire harnesses There must be no pinching rubbing or stretching of either component Use zip ties to secure these items At full droop cycle the steering from lock to lock while observing the reaction of these components Reposition them if needed Reinstall the rear wheels and lower the vehicle to the ground Torque the lug nuts according to the wheel manufacturers recommendations Position your vehicle on a smooth flat hard sur
5. Preset the 4 link upper control arm 88 RM31123 to an initial setting of 18 625 center to center install the coupler end into the OE upper arm mounting pocket at the frame using the previously removed OE bolt and hardware Be sure there 15 at least 1 of thread engagement Photo 24 Attach the rubber bushing end of the upper arm to the upper mount on the axle using the previously removed OE bolt and hardware DO NOT tighten the rubber bushing until the vehicle is on the ground to avoid bushing preload Repeat steps A E on the opposite side Revised 4 15 14 The upper and lower arms may need to be be readjusted 250 after the installa tion is complete for proper pinion angle and clearance of other components It is highly recommended that the OE rockers and body tub are trimmed near the front edge of the tire to prevent tire damage at full compression Extending the control arms too far to allow additional room for the tire can cause too little thread engagement and other items to contact during suspension travel Photo 23 Photo 24 Step 10 Rear Brake Line Installation 1540 A NOTE NOTE On the driver side unbolt the brake line bracket from the frame rail Disconnect the rubber hose from the steel line at the frame plug the steel line to prevent excessive fluid loss Secure the supplied 90 degree brake line mounting bracket to the frame using the previously removed OE bolt Positi
6. 1 installation by removing the following parts from the vehicle Tires wheels Automatic transmission skid plate equipped Transfer case skid plate Front and rear drive shafts Front 2 gas tank skid plate bolts at cross member and loosen the remaining bolts The gas tank should be removed completely from the vehicle for a clean and safe removal of the rear lower OE control arm brackets on the passenger side It can be done at this time or later when the rear suspension 15 started Go to step 8 for tank removal Cy gt 2012 vehicles will require the exhaust loop bypass modification to clear the front lower control arm the driver s side Use part RE4531 Step 1 Three Piece Cross Member Installation A NOTE NOTE Prepare the new crossmember RE4521 by loosely installing the 2 supplied 1 2 X 3 and 2 1 2 X 4 3 4 bolts through all 3 crossmember mount pieces RM21051 Driver RM21056 center and RM21050 Passenger before install it into the vehicle photo 1 The shorter of the two 1 2 bolts install from front to the back and the longer of the two installs from back to the front Install the 4 3 8 X 1 flat head bolts into the bottom of the crossmember and tighten to 15 ft Ibs then tighten the previously installed 1 2 bolts to 80 ft Ibs photo 1 Installing the hardware in this fashion will allow the removal of the center crossmem ber section without removal of the front lower
7. 135 drvr into place and secure to the frame using C clamps Using the mounting holes in the bracket as a guide drill the center control arm mounting bolt hole using a 9 16 drill bit Photo 20 Drill the 1 upper and 2 lower holes using a 1 2 drill bit Photo 21 Secure the bracket to the frame using the supplied 1 2 X 1 1 2 bolt 9 16 X 4 bolts and the dual nut plate 35 RM24143 Torque the 1 2 bolt to 80 ft lbs Do not tighten the 9 16 bolt at this time Photo 20 amp 21 Secure the 2 lower bracket mounting holes to the frame using the 2 supplied 1 2 X 1 1 2 bolts 2 nut plate 35 RM24028 Photo 22 Revised 4 15 14 Photo 20 Photo 21 Photo 22 Step 9 Upper and Lower Control Rear Arm Installation A Prepare the rear of the vehicle for control arm and component installation by removing the following items shocks sway bar links coil springs track bar brake line brackets at the frame e brake cables at the axle Preset the 4 link lower control arms 88 RM31015 to 36 25 center to center and install the coupler end into the 4 link rear frame bracket 86 RM24135 drvr and 86 RM24138 pass using the supplied 9 16 X 4 bolt hardware Photo 23 Attach the rubber bushing end of the lower arm to the lower control arm mount on the axle housing using the OE bolt and hardware DO NOT tighten the rubber bushing until the vehicle is on the ground to avoid bushing preload
8. 25 ft lbs Do not tighten the axle end until the final length check at the end of the installation and the vehicle is sitting on its own weight Photo 5 Photo 6 Photo 7 Revised 4 15 14 Step 3 Front Brake Line Installation RE1530 A B NOTE On the driver side unbolt the brake line bracket from the frame rail Disconnect the rubber hose from the steel line at the frame plug the steel line to prevent excessive fluid loss Secure the supplied 90 degree brake line mounting bracket to the frame using the previously removed OE bolt Position the bracket so it is below the mounting bolt Left and Right lines are supplied in the kit Be sure to check that the caliper mounting block points the hose away from the caliper prior to install Photo 8 Thoroughly clean all mating surfaces of the OE steel brake line and caliper mounting surfaces Using the supplied copper banjo washers and OE banjo bolt install the brake hose to the caliper Torque the banjo bolt to 23 ft Ibs Insert the new hose assembly thru the previously installed bracket and secure with the supplied spring clip 2011 vehicles have a brake hose routing that bolts near the shock mount The hoses supplied with the kit will not route in the same fashion Route the hose and ABS wire together and secure with zip ties out of harms way Carefully thread the OE steel line into the new Stainless Steel brake hose and tigh
9. DWARE PACK REAR SWAY BAR 2 1 2 13 X 2 1 2 HEX BOLT GR 8 2 1 2 13 NYLOCK NUT GR 2 1 2 USS FLAT WASHER RE1380 FRONT BUMP STOP 2 90 RM42520 FRONT BUMPSTOP PAD 1 HW1060 HARDWARE PACK FRONT BUMP STOPS 2 3 8 16 X 2 SELF TAPPING BOLT E1530 FRONT BRAKE LINE KIT FRONT BRAKE LINE 24 HWC15030 HARDWARE PACK FRONT BRAKE LINE R 2 1 2 90 DEGREE BRACKET 2 RETAINER CLIP 2 SELF TAPPING SCREW 4 WASHER E1540 REAR BRAKE LINE KIT REAR BRAKE LINE 24 HWC15040 HARDWARE PACK FRONT BRAKE LINE RETAINER CLIP SELF TAPPING SCREW R 2 1 2 90 DEGREE BRACKET 2 2 4 WASHER Revised 4 15 14 RE1673 USTABLE FRONT TRACK BAR 1 88 RM30660 FRONT ADJ TRACK BAR ADDITIONAL REQUIRED EQUIPMENT BOX PURCHASED SEPARATELY RX 711 FRONT SHOCKS RX 712 REAR SHOCKS RE1883 365 FRONT DRIVE SHAFT RE1883 385 FRONT DRIVE SHAFT 2012 AUTO TRANS RE1810 FRONT TRANSFER CASE YOKE RE1887 430 REAR DRIVE SHAFT RE1805 REAR DRIVESHAFTS FLANGE ADAPTER NN ADDITIONAL OPTIONAL EQUIPMENT BOX PURCHASED SEPARATELY 1 RE4522 JEEP TRANSMISSION SKID PLATE KIT 1 35 RM31023 SKID PLATE 1 HWC15003 HARDWARE PACK SKID PLATE Front Suspension and Component Installation Vehicle Preparation 1 2 Properly support the vehicle off the ground under both the frame and axles Prepare the vehicle for the front Rubicon 3 cross member RE452
10. M11205 to the stow away brackets using the supplied 1 2 hardware photo 17 amp 18 Photo 17 Photo 18 Step 8 Rear Control Arm Bracket Installation FUEL TANK REMOVALL The fuel tank removal should be done when there 15 less than 1 8 tank of fuel in the tank to avoid excess fuel sloshing weight Special tools are not required for the removal of the fuel tank All plastic clips should come apart by squeezing the outer portion of the clip and gently pulling apart The following connections need to be removed supply and return at the front of the tank large plastic line at the charcoal canister vent hose at fuel tank and the fuel filler hose DO NOT use excessive force damage to the fittings or seals may result Before lowering the tank back out the bolt from the right rear lower control arm to avoid dragging the side of the tank on the end of the bolt Do not completely remove the bolt at this time Revised 4 15 14 Caution With the fuel tank removed there may be fuel vapors present Use good judgment when drilling cutting and welding near the fuel system components A the passenger side with the axle supported remove the passenger side upper and lower control arms from NOTE B the vehicle Be sure to leave the driver side control arms in place to keep the rear axle from rolling over Using a suitable cutting tool abrasive cutoff wheel Sawz all etc cut off the lower control arm mounting pock ets f
11. PRESS 3 5 FRONT COIL 2 DOOR RE1371 4 DOOR FRONT COIL SPRINGS 2 RUBICON EXPRESS 3 5 FRONT COIL 4 DOOR RE1375 2 DOOR REAR COIL SPRINGS 2 RUBICON EXPRESS 3 5 REAR COIL 2 DOOR RE1376 4 DOOR REAR COIL SPRINGS 2 RUBICON EXPRESS 3 5 REAR COIL 4 DOOR RE4521 FRONT CROSSMEMBER ASSY RM21055 CROSSMEMBER BRACE CAPTIVE NUT RM21051 CROSSMEMBER MOUNT LEFT RM21056 CROSSMEMBER MOUNT CENTER RM21050 CROSSMEMBER MOUNT RIGHT RM21053 CROSSMEMBER BRACE DRVR RM21054 CROSSMEMBER BRACE PASS 1 2 13 X 1 1 4 GR 8 BOLT 1 2 USS FLAT WASHER 1 2 LOCK WASHER HWC10270 HARDWARE PACK CROSSMEMBER 1 2 13 3 HEX BOLT GR 8 1 2 13 X 4 3 4 HEX BOLT GR 8 3 87 16 X 1 HEX BOLT GR 8 1 2 13 X 1 1 2 HEX BOLT GR 5 optional skid Plate bolts 1 2 SAE HARDENED FLAT WASHER 1 2 13 NYLOCK NUT GR 1 2 USS HARDENED FLAT WASHER 1 2 13 X 1 1 4 GR 8 BOLT 1 2 LOCK WASHER HWC15034 HARDWARE PACK CROSSMEMBER 12 1 75 X 140MM HEX BOLT GR 10 9 12MM 1 75 STOVER NUT 12MM FLAT WASHER COP WN RE4543 FRONT UPPER ARMS w BRACKETS 88 RM31006 FRONT UPPER CONTROL ARM HWC15007 HARDWARE PACK 35 RM14009 7 8 HEIM SPACER 86 RM24020 UPPER ARM MOUNT BRACKET DRVR 86 RM24024 UPPER ARM MOUNT BRACKET PASS HWC15008 HARDWARE PACK FRONT ARM MOUNT 1 2 13 X 1 1 4 HEX BOLT GR 8 1 2 13 X 1 1 2 HEX BOLT GR 8 1 2 HARDENED FLAT WASHER 1 2 13 STOVER NUT GR 9 16 12 X 3 HEX BOLT GR 8
12. Revised 4 15 14 RUBICON EXPRESS 3290 MONIER CIR RANCHO CORDOVA CA 95742 866 533 7706 www Rubiconexpress com Installation instructions for Rubicon Express J K Extreme Duty 3 5 4 Link Suspension Systems J K4423 2 Door and J K4443 4 Door Congratulations on purchasing the ultimate suspension package available for the Jeep Application Notes The J K long arm kit is not a complete kit this suspension system requires additional parts are purchased separately At minimum shocks and drive line components will also be needed for a complete installation This kit is designed to replace the stock short arm configuration I nstallation of this system will require the removal of front and rear lower control arm mounts from the frame Additionally the front upper control arm mount will need to be modified to accept the new upper control arm mount This kit does not require modifications to the exhaust system for 2007 2009 models however it is recommended that the exhaust from the transmission cross member back is removed prior to and replaced after installation to better access the frame rail during rear bracket installation NOTE 2010 and UP will require modification of the driver s side down pipe RE4531 exhaust loop bypass The transmission skid plate must be removed and will not be reinstalled due to drive shaft clearance Due to lift height and suspension travel it is absolutely necessary that a front and rear U joint style driv
13. be sure all parts are present before disassembling the vehicle Included instruc tions are guidelines only for recommended procedures and in no way are meant to be definitive Installer is responsi ble to insure a safe and controllable vehicle after performing modifications Do not perform test drives on public roads with partially completed installations Always double and triple check your work before use ESP WARNING NOTE The 2007 J eep Wrangler J K is equipped an Electric Stability Program ESP This system is designed to help control the vehicle in times of uncertain traction conditions and roll stability Due to the complex nature of this program Rubicon Express strongly suggest that after lifting the vehi cle it is returned to the dealer for a computer flash to re address tire size and proper ESP control set tings Rubicon Express also recommends that you become familiar with the ESP controls and how the different level of settings can help you to keep better control of your vehicle REQUIRED TOOLS Basic mechanics hand tools Jack stands Vehicle hoist Floor jacks Fluid drain pan Brake Bleeding New DOT approved brake fluid Drill motor amp drill bits Tapered 1 7 15 degree Tie rod end puller Snap On part number R121 Plasma cutter reciprocating saw w metal cutting blades or cutting wheels for angle or die grinder Revised Kit contents 4 15 14 1370 2 DOOR FRONT COIL SPRINGS 2 RUBICON EX
14. control arms should transmission service become necessary Support the transmission transfer case assembly at the rear output shaft Remove the 3 transmission mount nuts at the center of the crossmember and 4 crossmember nuts at the frame rail 2 per side Using a jack gently lift the transmission transfer case assembly to remove the weight on the OE crossmember Remove the 4 OE crossmember bolts 2 at each frame rail photo 2 Raise the new Rubicon Express crossmember RE4521 into the OE mounts with the control arm mounting pock ets facing toward the front of the vehicle Secure the crossmember RE4521 and braces RM21053 Driver and RM21054 Pass by placing the cross member braces up to the front side crossmember mounting holes and stalling the 4 supplied 12mm x 140mm bolts and hardware through the crossmember braces and OE mounts Photo 3 Secure the cross member braces RM21053 Driver and RM21054 Pass to the frame by inserting the 2 captive nuts RM21055 into the frame holes and inserting the 2 1 2 X 1 1 4 bolts and washers Tighten to 55 ft Ibs photo 3 Lower the transmission reinstall and tighten transmission mount nuts Re check and tighten all hardware Photo 1 Revised 4 15 14 Photo 2 Photo 3 Step 2 Upper and Lower Front Arm Installation NOTE NOTE NOTE Unbolt the front track bar and remove it from the vehicle Save the hardware for reinstallation Remove the shocks on bo
15. e shaft be used in conjunction with this lift Safety Warning Suspension systems or components that enhance the off road performance of your vehicle may cause it to handle differ ently on and off road than it did from the factory Care must be taken to prevent loss of control or vehicle rollover during sudden maneuvers Failure to drive the vehicle safely may result serious injury or death to driver and pas sengers We recommend you always wear your seat belt drive safely and avoid quick turns and other sudden maneu vers Constant maintenance is required to keep your vehicle safe Thoroughly inspect your vehicle before and after every off road use Installation Warning All procedures described in these instructions were performed while the vehicle was properly supported on a vehicle lift Use caution when supporting the vehicle as removing and installing parts will change the vehicle center weight Rubicon Express recommends that chassis support jacks are always used at the front and rear of the vehicle during the installation of a suspension system We recommend that certified technicians perform the installations of our products Attempts to install these products with out knowledge or experience may jeopardize the safety of the vehicle These instructions only cover the installation of our products and not include factory procedures for disassembly and reassembly of factory components Read instructions from start to finish and
16. face i e concrete or asphalt Verify all coils are properly seated shocks installed and lower the vehicle Torque all control and track bar rubber bushing hardware Torque the 9 16 to 130 ft lbs or manufacturers specifications where OE bolts are used Properly bleed brake lines according to the manufacturers assembly manual Check for leaks and a firm pedal Make sure the steering wheel is centered and manually disable the factory ESP system before the first test drive Refer to the owners manual for the disable procedure Drive the vehicle forward and backward a few feet to be sure that the axle is adjusted properly and the vehicle 15 tracking a straight line Adjust front track bar for axle center if necessary Be sure to note the location of steering wheel while driving a straight line and any driveline vibrations T Trans Engine a a __ Proper Geometry for Drive Shafi Wyle Minimum factory caster and maximum factory toe in seems to work well with these front ends see Troubleshooting as well Adjust upper control arms if necessary for proper front castor angle and rear pinion angle Below is a diagram of the proper pinion angle for a CV style drive shaft See Troubleshooting also Retighten all bolts after 50 miles and again after every off road excursion After all adjustments have been made Rubicon Express recommends that your local J dealership
17. hten the 9 16 bolt to 90 ft lbs Photo 28 C Install the supplied 9 16 X 3 bolt from the front to back through the bracket and OE track bar Install locking nut on bolt but do not tighten at this time DO NOT tighten until suspension install is complete and vehicle is sitting on the ground Revised 4 15 14 Photo 28 Step 12 Rear Bump Stop and Coil Spring Installation A Install the new rear bump stop pad 86 RM22016 to the rear axle OE bump stop pad using the 2 3 8 X 3 4 bolts and hardware Photo 29 B Carefully lower the rear axle to ease in the new coil spring installation Using the factory isolators install the rear coil springs into the spring buckets and raise the rear axle into place Make sure the coil spring seats properly on the lower spring perch NOTE Be sure to reinstall the factory isolators before raising the springs into place Photo 29 Revised 4 15 14 Step 13 Rear Sway Bar End Link Installation RE1157 A Install the new sway bar end links 35 RM11065 to the sway bar with the supplied 1 2 hardware using the flat washer to the outside to prevent the bolt head pulling through the eyelet Install the new sway bar end links 35 RM11065 the sway bar with the supplied 1 2 hardware using the flat washer to the outside to prevent the bolt head pulling through the eyelet Photo 30 Install sway bar end links to the axle mounting points with the previously removed
18. ink mount welded to the axle tube Attach using the supplied 1 2 X 1 1 2 bolt and hardware Torque to 75 ft lbs photo 12 C Install the steel pin RM11140 through the upper hole of the relocation bracket using the supplied 12mm X 35mm bolt flat and lock washers Tighten to 50 ft lbs photo 13 Photo 12 Photo 13 Photo 14 D Assemble the end link RM11175 jam nut HW3037 and 1 2 female rod end QA1CFR8 Using the supplied 1 2 X 2 1 2 bolt and hardware secure the rod end to the sway bar inserting the hardware from the inside out Be sure to install a misalignment spacer RM11155 on each side of the rod end photo 14 E Rotate the end link as shown and secure it to the pin on the axle with the supplied retainer pin HWC12005 Tighten the jam nut to the rod end while holding the rod end so you do not twist the link This will allow for eas ier removal photo 15 Revised 4 15 14 Photo 15 Photo 16 Rubicon Edition Installation NOTE If using the kit as sway bar links only for the J Rubicon Edition with a factory sway bar disconnect replace the hardware in step D with the 1 2 X 2 1 2 bolt Use the sleeve inside the bushing end of the link and the washer on the outside of the link photo 16 F Remove the OE nut from the bottom of the driver and passenger side front body mount and install the end link stow away brackets RM11200 Install the aluminum stow away pins R
19. moval instal lation freight or incidental or consequential damages are expressly excluded from this warranty Rubi con Express 15 not responsible for damages and or warranty of other vehicle parts related or non related to the installation of Rubicon Express product A consumer who makes the decision to modify his vehicle with aftermarket components of any kind will assume all risk and responsibility for potential damages incurred as a result of their chosen modifications Warranty coverage does not include consumer opinions regarding ride comfort fitment and design Warranty claims can be made directly with Rubicon Express or at any factory authorized Rubicon Ex press dealer Claims not covered under warranty Parts subject to normal wear this includes bushings shock absorbers driveshafts ball joints tie rod ends and heim joints Discontinued products at Rubicon Express s discretion Finish after 90 days Rubicon Express accepts no responsibility for any altered product improper installation lack of or im proper maintenance Or improper use of our products Rubicon Express PT MEG Super Ride bushings are covered by the Rubicon Express Advan tage Lifetime Warranty and will be replaced in the event of failure for the life of the product
20. ngs remove the bump stop and insert it into the coil Then slide the coil over the stock axle mount and re install the bump stop bolts photo 9 Photo 9 Step 5 Front Shock Installation A B Raise the shock relocation brackets 86 RM24063 drvr 86 RM24064 pass into place from underneath the vehicle Attach the relocation brackets to OE shock bracket using the supplied 3 3 8 X 1 bolt and hardware Do not tighten these bolts at this time Photo 10 Secure the front of the relocation bracket using the 1 4 X 1 bolt and hardware Do not tighten these bolts at this time Install the lower portion of the shock to the shock relocation bracket using the supplied 1 2 X 4 1 2 bolt spacer 35 RM31024 and 1 2 hardware Photo 10 Install the spacer 35 RM31024 inside the OE shock mount to keep the mount from collapsing when tightening D Torque shock relocation bracket hardware at this time Torque the 1 2 hardware to 65 ft lbs Torque the 3 8 hardware to 35 ft lbs Torque the 1 4 hardware to 12 ft Ibs Revised 4 15 14 It will be necessary to raise the axle and put load against the coil springs to install the front shocks BE SURE that the vehicle is properly supported when doing so Photo 10 Step 6 Front Track bar nstallation A NOTE Set the adjustable track bar 88 RM30660 at an initial setting of 32 7 8 center to center Thi
21. on the bracket so it is above the mounting bolt Left and Right lines are supplied in the kit Be sure to check that the caliper mounting block points the hose away from the caliper prior to install Photo 25 Thoroughly clean all mating surfaces of the OE steel brake line and caliper mounting surfaces Using the supplied copper banjo washers and OE banjo bolt install the brake hose to the caliper Torque the banjo bolt to 23 ft Ibs Insert the new hose assembly thru the previously installed bracket and secure with the supplied spring clip Carefully thread the OE steel line into the new Stainless Steel brake hose and tighten DO NOT allow the stainless steel brake hose to twist when tightening to the bracket or OE brake line Twists can cause kinks in the brake hose assembly during suspension travel Repeat steps A F on passenger side Revised 4 15 14 Photo 26 Photo 27 Step 11 Rear Track Bar Bracket nstallation RE1607 A Place the new track bar bracket over the factory track bar mounting point on the axle while aligning the two 3 8 holes on the back side of the lower control arm bracket Loosely install the two 3 8 bolts washers and nuts through the lower control arm bracket and track bar bracket Photo 28 B Install the 9 16 X 3 1 2 bolt through the factory track bar location being sure to use the supplied spacer to keep the factory bracket from collapsing Tighten the two 3 8 bolts to 35 ft lbs then tig
22. rom the frame After trimming the lower control arm mounting pocket sand the cut area smooth Clean the area thoroughly and paint the exposed metal with quality paint Photo 19 DO NOT cut into the frame rail This will weaken the frame structure considerably NOTE For maximum travel it may be necessary to trim 1 off the rear body mounts Raise the pass side rear lower control arm mount bracket 86 RM24138 pass into place and secure to the frame using the previously removed OE fuel tank skid plate retaining bolt Clamp the bracket firmly in place against the frame Using the mounting holes in the bracket as a guide drill the center control arm mounting bolt hole using a 9 16 drill bit Drill the upper and front lower holes using a 1 2 drill bit Secure the bracket to the frame using the 1 2 X 1 1 2 bolt 9 16 4 bolt and the supplied dual nut plate 35 RM24143 Torque the 1 2 bolt to 80 ft lbs Do not tighten the 9 16 bolt at this time Secure the front lower bracket mounting hole to the frame using the supplied 1 2 X 1 1 2 bolt and nut plate 35 RM24028 On the driver side the bracket will be located on the frame by measuring 11 1 8 forward from the small square hole near the rear upper control arm mounting bolt Photo 19 The bracket is contoured to fit perfectly against the overlap in the frame Raise the driver side rear lower control arm mount bracket 86 RM24
23. s measurement may vary due to the weight of your vehicles front end We advise to pick a common point on both sides of the axle and then cross measure to the opposite side frame rail By cross measuring you are assuring the axle 15 centered under the vehicle Using the OE track bar bolt install the bushing end into the axle mount Attach the heim joint end of the track bar to the OE frame mount using the supplied misalignment spacers and the OE bolt The bend on the track bar will be with the elbow up to clear the front differential cover It may be necessary to use a ratchet strap to pull the axle to the driver s side and install the track bar Otherwise wait until the vehicle is on the ground under its own weight to install the track bar at the frame end Moving the steering wheel back and forth will as sist connection the track bar if the vehicle is on the ground Revised 4 15 14 Step 7 Front Sway Bar End Link Disconnect nstallation NOTE This kit contains all parts necessary to install sway bar disconnects sway bar links on Jeep J Wrangler For Rubicon models with the factory electronic sway bar dis connect it is optional to install the kit as fixed links or as an optional method of discon necting the front sway bar Unbolt and remove the front sway bar end links from the vehicle B Locate the new Rubicon sway bar axle mount tab RM20815 Drvr and RM20816 Pass to the inside of the OE sway bar end l
24. stall the upper control arm mount bracket 86 RM24024 passenger side to the existing previously modified upper control arm bracket Secure to the OE mount using the supplied 1 2 X 1 1 4 bolt and hardware in the front hole photo 4 amp 5 Secure the rear of the bracket in place using the supplied 2 1 2 X 1 1 2 bolts 2 1 2 X 1 1 4 bolts hardware and 3 nut plates 35 RM24028 in the existing holes in the frame photo 4 amp 5 Pre set the 4 link upper control arm to an initial setting of 22 5 center to center install the clevis end of the upper arm to the bushings on the front axle using the previously removed OE hardware photo 6 Insert the Heim spacers 35 RM14009 into the rod end Revised 4 15 14 Install the rod end of the upper arm to the mounting pockets on the brackets using the supplied 9 16 X 3 bolts and hardware Torque the OE upper control arm mounting bolts to 75 ft lbs and the supplied 9 16 bolts to 130 ft Ibs Pre set the 4 link lower control arm to an initial setting of 37 5 center to center install the Super Flex end of the lower arm to the mounting pocket on the new transmission cross member RE4521 using the supplied 9 16 X 4 bolts and hardware photo 7 Install the bushing end of the lower to the mounting pocket on the axle using the previously removed OE bolts and hardware Repeat steps D N on the driver side Torque the lower control arm OE mounting bolts to 1
25. ten DO NOT allow the stainless steel brake hose to twist when tightening to the bracket or OE brake line Twists can cause kinks in the brake hose assembly during suspension travel Repeat steps A through F on passenger side Bleeding of the brake system will need to be performed after the rear brake hoses changed out Bleeding should be done according to factory service manual specifica tions Use extreme caution to not let the master cylinder run out of fluid damage to the ABS unit will occur Photo 8 Revised 4 15 14 Step 4 Front Bump Stop and Coil Spring Installation A Place the front bump stop 90 RM42520 on the center of the lower spring mount on the axle tube Insert a cen ter punch thru the center and mark the hole to be drilled Drill the marked hole to 5 16 use the supplied 3 8 x 2 self tapping bolt to secure the bump stop 90 RM42520 to the lower spring cup C Carefully lower the front axle to ease installation of the new coil spring D sure the OE coil spring isolator 15 still in place on the upper tower raise the small diameter end of the coll NOTE into the upper spring bucket and over the lower spring cup and bump stop Then raise the axle to seat the up per mount and rotate the coil to properly index in the lower mounts If the axle cannot be dropped far enough from the frame due to brake line or ABS wire length to install the coil spri
26. th sides of the vehicle the shocks and hardware will not be reused on 5 5 systems It may be necessary that you slightly raise the axle to unload the shocks for removal Lower the front axle enough to remove the coil springs from the front spring pockets Keep the factory isolators for re installation Be sure to support the front axle while the springs are removed On the passenger side with the axle supported remove the passenger side upper and lower control arm from the vehicle Be sure to leave the driver side control arms in place to keep the front axle from rolling over IMPORTANT Be sure not to cut into fuel or brake lines DO NOT cut into the frame rail This will weaken NOTE the frame structure considerably Using a suitable cutting tool abrasive cutoff wheel Sawz all etc cut off the front lower arm mounting pocket Af ter cutting the lower arm mounting pockets sand the frame smooth Clean the area thoroughly and paint the ex posed metal with quality paint The lower mount is made of multiple pieces laminated to the frame All of the lower mount needs to be removed to expose the bare frame Using a suitable cutting tool abrasive cutoff wheel Sawz all etc trim off the outer portion of the front upper con trol arm mounting pocket cut line shown in photo After trimming the upper control arm mounting pocket sand the cut area smooth Clean the area thoroughly and paint the exposed metal with quality paint In
27. uce speed We will gladly answer any questions concerning the design function maintenance and correct use of our products Please make sure that the Dealer Installer explains and delivers all warning notices warranty forms and instruction sheets included with Rubicon Express product Application listings in this catalog have been carefully fit checked for each model and year denoted However Rubicon Express reserves the right to update as necessary without notice and will not be held responsible for misprints changes or variations made by vehicle manufacturers Please call when in question regarding new model year vehicles not listed by specific body or chassis styles or vehicles not Originally distributed in the USA Please note that certain mechanical aspects of any suspension lift product may accelerate ordinary wear of original equipment components Further installation of certain Rubicon Express products may void the vehicle s factory warranty as it pertains to certain covered parts it is the consumer s responsibility to check with their local dealer for warranty coverage before installation of the lift Warranty and Return Policy Rubicon Express warranties its full line of products to be free from defects workmanship and materi als for the life of the product Rubicon Express s obligation under this warranty Is limited to repair or replacement at Rubicon Express s option of the defective product Any and all costs of re
Download Pdf Manuals
Related Search