ADVANCE ADAPTERS INC. RUBICRAWLER CRAWL BOX JEEP
Contents
1. 9 09 Paso Robles CA 93447 PAGE 10 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 Transfer Case Installation l 10 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 Install transfer case shifter bracket with supplied 6 mm hex head bolts and lock washers to the RubiCrawler shift hous ing See Figure 18 Remove orange plastic retainer clip from transfer case shift cable and discard Lubricate the lip seal on the back of the RubiCrawler with ATF 4 Use Figure 20 as a guide for proper clocking rotation Shift the transfer case into any gear other than neutral The RubiCrawler has amachined mark that designates the stock rotation hole set Install the transfer case back into the vehicle by lifting it into place and rotating the rear yoke until the splines engage Use stubby 9 16 wrench to torque transfer case nuts to 25 30 ft Ibs Insert the transfer case shift cable into the transfer case cable bracket previously installed The cable is secured with the supplied cable retaining bracket and 1 4 20 button head bolt The retaining bracket is mounted on the transfer case side of the shift cable bracket Shift the transfer case into 2wd high by pulling the transfer case shift lever towards the front of the vehicle Verify that the transfer case cable travels forward of the heim stud by 1 8 3 16 See Figure 22 Shift transfer case into 4wd low by pushing the transfer case shift lev2. CRAWL BOX JEEP WRANGLER JK 2007 2011 Remove drive shafts and any skid plates that prevent access to the transfer case or the transmission RYO RAL BAYA AS transfer case the rod end from the transfer case Caution must be used to remove the stock shifter cable as prying on one side can crack the stock shifter cable rod end Figure 1 Rod End Removal removing the 6 nuts from the transfer case studs Using astubby 9 16 wrench makes this step much easier bracket mounted to the tailhousing by squeezing the tabs on the orange plastic retaining clip and pulling down on the cable Clip will notbe reused Then remove the three 10mm bolts securing the transfer 1 YF case shifter bracket to the tailhousing B Raise PN 15 1000 See Figure 2 or some other device to support the transmission pan to supportits k AEN Puller weight Take caution to avoid denting the pan and damaging the transmission Figure 3 Custom Puller Method Remove the foot mount from the Figure 4 Pry Method tailhousing of the transmission by unbolting the four 10 mm hex head bolts 8 Unboltthe fuel system tab from the transmission tailhousing 9 Remove the wiring harness from the tailhousing by prying up the plastic barb on the driver s side of tailhousing 10 Remove the spud shaft by following one of the three suggested methods below The end of the spud shaftis tapped M10 1 5 1 Slide Hammer factory service m
3. The RubiCrawler must be shifted when the transmission is in neutral and the vehicle speed is less than 2 mph The RubiCrawler can be shifted at a complete stop but it is easier to shift the unit when at a very slow roll Do NOT try to force the shift levers as serious damage to the shifters or unit can occur Serious damage to the RubiCrawler can occur if the proper shifting instructions are not followed Shift Knobs and Shift Patterns The shift knobs and patterns can be seen below and on the next page 42R65 3033 i 1 Te SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 14 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 2 3 11 RUBICRAWLER CRA
4. more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA New Item 9 09 P O Box 247 4320 Aerotech Center Way Paso Robles CA 93447 Telephone 800 350 2223 Fax 805 238 4201 PAGE 9 of 18 Page Rev Date 1 11 10 Figure 21 RubiCrawler cable shifter adjustment verification See Step 4 of the RubiCrawler Shift Cable Installation SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item
5. of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 18 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 09 19 13 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 a y A notch will need to be cut into the fuse box for the wire to run out which _ can also be seen in Figure 3 The ground can be run along the side of the fuse block to the ground terminal on the passenger fender next to the fuse box JeepTJ Route the power and ground through the firewall to the fuse box behind the glove box Mount the ground to the firewall The power should be plugged into the fuse block in an empty ignition hot fuse slot Wiring Schematic PUBICFAwWLEF CONTROL MODULE I F LIF Ard sf z i i Lit I tk 1 ae i fz iy cy i fol i i a ae i f l 1 SOLDERS TO THE STOCH tt d a i Ki f i T CONRECTOR REMOVED FROM E m 5 a TRE WEHILLES WIFIHG HARPHESS a CONNECTS TO ac Ott H FUBICRAWLEF ie iz ea FUSI TION SWltlH fo y mm EAU CES Ay oan i es ee ae PLUG SOLDERS TO WEHICLI TE ae a WIFINMG HEEHELS wWHEFE STOCs COMAECTOR wat PEHDOWED BL ace 15 GROUND i P
6. tor and the three wire delphi connector included in this kit 5 The purple wire is a signal wire for an AeroForce gage P N 716091 which is an optional item that can be purchased separately Jeep JK It is recommended to run the purple wire up through the floor grommet directly over the rear face of the transmission This will bring it up under the console which will be close to the required location to mount to the AeroForce gage sold sepa rately Jeep TJ Route the purple wire through the firewall with the power and ground 6 Jeep JK Run the red power and black ground wires along the frame on the passenger side up to the fuse box Make sure to safely zip tie the wiring away from the exhaust any pinch points or other hot objects The Fuse attaches in the fuse box in the empty fuse slot labeled M14 TTOW BUX Refer to the under side of the fuse box lid for the proper location Make sure to install it in the same direction as seen in the figure below Figure 4 JK Ground Terminal SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly
7. 0 BRACKET JK SHIFT BASE PLATE 33 4 720057 6MMX1 00X 16MMH H CSS 16 1 42R601 BRACKET PIVOTMOUNT 34 4 722513 LOCKWASHER 1 4 PLT 17 1 42R602 HANDLEASSEMBLY JK DRIVER 35 4 722523 1 4 USSFLATWASHERPLTD 18 1 42R603 HANDLE ASSEMBLY JK PASSENGER 36 1 722523 1 4 USS FLAT WASHER PLTD 19 1 42R608 BARREL CABLE 37 1 723141 5 16 I8NYLOCHEXNUT 20 1 42R609 SPRING WAVE 38 2 723740 3 8 16X1 1 2 S H CS 21 1 42R610 BRACKET BARREL RETAINER 22 1 42R611 SHAFT JK PIVOT 23 1 42R612 BRACKET JK INTERIOR STOCK CABLE MOUNT 24 8 42R616 BOLT 1 4 20 X 5 16 B H C S 25 1 42R616 BOLT 1 4 20 X 5 16 B H C S 26 2 42R617 BOLT 1 4 20 X 3 8 B H C S PLAIN The JK s retain the stock shifter cable on the transfer 27 1 42R618 BOLT 5 16 18 X 3 25 H H C S case The bushings on the shifter cable may be worn 28 1 42R620 BRACKET OEMJK T CASE SHIFTER i 2 1 42R621 BRACKET_JK STOCK CABLERETAINER or if broken Aa removing may need to be replaced 30 1 42R651 KNOB JKRUBICRAWLER The Chrysler P N is 68064273AA SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter com
8. 010 with the factory automatic transmission 42RLE This particular kit RUBI JKA includes twin stick shifters for the 2007 2010 Jeep JK Wrangler with the factory NP241 and will not work with an aftermarket transfer case such as the Atlas SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 4 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 Disassembly Preparation For Assembly l Disconnectthe breather hose and the wiring harness from the Asshownin Figure J using two flat head screw drivers remove Remove the transfer case from the vehicle by Remove the transfer case shift cable from the Use an Advance Adapters Uni RUBICRAWLER
9. 2 Install the shifter base plate over the Figure 25 Insta il Brachetto mounting studs and secure using the 4 Stock Cable Shifter OEM nuts See Figure 24 3 Install 5 8 jamb nut onto cable Remove cable barrel from the shifter pivot assembly and thread completely onto cable Leave barrel finger tight Thread heim jointentirely onto cable end and tighten 1 4 jam nut Figure 26 Install RubiCrawler Cable Retaining Clip 4 Snap the transfer case cable into the transfer case cable bracket See Figure 25 5 Install the stock plastic heim joint over the mounting stud on the shifter pivotassembly 6 Slide cable barrel into shifter pivot assembly and attach retaining clip using supplied 5 16 button head bolt See Figure 26 7 Boltdown the shifter pivot assembly to the lower base plate using the 7 supplied 1 4 20 x 5 16 button head bolts Start all bolts before final torquing See Figure 27 8 Boltstock cable retaining bracket to base plate with 2 supplied 1 4 20 x 3 8 button head bolts We recom mend sliding the bracket completely forward in its slots to maximize dash knob clearance See Figure 28 Figure 28 Install Stock Cable Retaining 9 Shiftthe transfer case into 4wd high and RubiCrawler Bracket and Adjust Handle Location SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or retu
10. ADVANCE ADAPTERS INC P O Box 247 4320 Aerotech Center Way Paso Robles CA 93447 P N RUBI JKA New Item 9 09 PAGE 1 of 18 Page Rev Date 09 25 15 Telephone 800 350 2223 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 Fax 805 238 4201 SECONDI ON o Optional Items No Qty Part No Description L 1 RUBI JKA GEAR BOX Kit also includes Part No Description 42R350 CHRYSLER RTV SEALANT 15 1000 UNI RAISE Drivetrain Lifing Device 42R540 BOLT M10 1 5 X 30mm BHCS 42R360 CHRYSLER ATF 4 Qty 4 Recommemded 4 720015 WASHER 10mm FLAT 42R370 42RLE Transmission Filter 10 720028 BOLT M10 1 5 X 35mm SHCS 4 720073 BOLT M10 1 5 X 25mm HHCS 2 1 42R800 CONTROL MODULE KIT THESE ITEMS ARE ASSEMBLED AND 3 1 42R JKS SHIFTER KIT amp JK CROSSMEMBER 1 4 303081 BUSHING IGUS 1 2 X 1 2 ADJUSTED FOR THE INSTALLATION 2 1 303121 NUT 1 2 13 HX JAM BLACK ZINC 3 1 303309 1 CABLE ATLASSHIFTER48 LENGTH1 TRAVEL 4 24 303311 HEATSHIELD FIREPROOFSLEEVE1 2 5 1 303313 ROD END FEMALE 1 4 28 6 1 303313 RODEND FEMALE 1 4 28 7 2 303335 KNOB MOUNT CABLE SHIFTER TJ S 4 303339 BOLT 1 4 28 X 75 F H C S 9 2 303341 BOLT 1 4 28 X 5 8 B H C S 10 1 42R320 BRACKET RUBICRAWLER FOOT MOUNT JK 11 1 42R441 BRACKET RUBICRAWLERCABLEMOUNT 12 1 42R580 BRACKET JK FUELLINESUPPORT 13 1 42R581 NUT CLIP ON 6MM 31 1 42R652 KNOB JKT CASE 14 1 42R582 S H C S 6MM 1 00 X 8 MM LONG 32 2 720040 SHCS 8MMX1 25X20MM IS 1 42R60
11. ED GES TO FUSE EBLUILE ul E I Lis FURFRLE 5 FOR sH SEPOFORPCE GA G SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores
12. LETIE BLACK 4 Tool List L DRILL 2 13 64 OR 5 25mm DRILL BIT af SOLDERINGIRON 4 HEATING ELEMENT HEAT GUN OR LIGHTER SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 16 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 09 19 13 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 Introduction The RubiCrawler Control Module was designed to integrate the vehicles wiring harness transfer case position switch and the RubiCrawlers position switch This module will alert the vehicle when the RubiCrawler is shifted into low so that the vehicle will allow you to control the locking differentials disconnect the sway bar JK only and disab
13. Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 8 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 head bolts and washers Torque to 40 ft Ibs See Figure 17 Boltthe top half of the factory rubber mount assembly to the RubiCrawler foot mount and the bottom half of the rubber mount to the cross member 7 Lower the powertrain back down onto the cross member and fasten the two halves of the rubber mount assembly together with the factory nuts 8 Reattach the fuel line tab to the RubiCrawler fuel line bracket with the factory bolt NOTE If you purchased the optional RubiCrawler of Pe Control Module 42R800 now is the best time to q _ gt 6mm Hex Head installit Refer to the RubiCrawler Contro
14. WL BOX JEEP WRANGLER JK 2 007 2011 Rub avler Shifter a ol T J Non Rubicon Knob ta Se de ae aie mr a ee Ka PAA RAEN iS Eea cy es j Es 5 arar mja Ap P TJ Shift Knobs Maximum Speed The Rubi Crawler should not be operated at engine speeds above 5000rpm when the transmission is in overdrive This over speed condition will cause damage to the bearings and geartrain in the RubiCrawler in addition to possible damage to other components in the TJ Rubicon Knob vehicle ADVANCE ADAPTERS INC LIMITED WARRANTY The RubiCrawler is guaranteed against defects in workmanship and materials for one year This warranty begins from the date the unit is shipped from Advance Adapters We log all units with a serial number at time of shipping The warranty is void as determined by Advance Adapters Inc by misuse abuse improper mainenance or installation and or alterations to the product These guarantees do not cover any outside labor shipping towing normal wear or any other unforseen events that that may occur due to failure of a unit Advance Adapters reserves the right to repair or replace any product Do not disassemble or attempt to repair the RubiCrawler as doing so will void the warranty just return the product as further described below All returns must have a returned goods authoriztion RGA prior to shipping the product and returns are to be sent prepaid freight Please call 1 800 350 2223 and
15. anual method Note aggressive use may be necessary SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 5 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 11 12 13 14 15 Interior Disassembly l RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 200 7 2 011 i Custom Puller recommended method Make a custom device to span the tailhousing without contacting the end of the shaft Thread a M10x1 5 bolt through tool and into the spud shaft See Figure 3 i Pry Method fast but only works on some vehicles Usea piece of sheet metal to protect the tailhousing and bolta large washer to the shaft Use a pry bar to pry the shaft loose tak
16. er towards the rear of the vehicle Verify that the transfer case travels 1 8 3 16 farther rearward Figure 24 Install Shifter than the heim stud Base Plate SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 11 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 11 Snap plastic heim joint over transfer case shift lever stud 12 Reinstall the transfer case breather hose and wiring harness 13 Reinstall drive shafts and skid plates Interior Installation 1 Placethetwo supplied 1 4 washers on driver s rear mounting stud as shown in the picture See Figure 23
17. ing care not to damage the tailhousing See Figure 4 Prepare a drip pan Removing the tailhousing will result in 2 4 quarts of transmission fluid loss depending on the angle of the drivetrain Remove the transmission tailhousing by removing the 11 hex head bolts and allow oil to drain for 10 minutes Inserta CLEAN shop rag into the back of the transmission as shownin the picture below to prevent contaminates from entering your transmis sion See Figure 5 Thoroughly clean the rear face of the transmission Use solventanda brass wire brush to clean all of the RTV off of the mating face and take caution to avoid any debris from entering the transmission or transmis sion bearing See Figure 6 It may be necessary to trim excess RTV that pro trudes up from the transmission pan onto the rear face of the transmission Excess RTV can prevent the RubiCrawler from fully mating to the transmission face Remove the spud shaftretaining clip from the groove near the end of the transmission output shaft A 1 1200 gt A Figure 7 Rear Bolt Location Removing the driver s seat will make the interior install easier but PRECAUTION needs to be taken The seat must be handled with care as the seat weight sensor is a sensitive calibrated unit and can be damaged if dropped or sat on when notin the vehicle To remove the seat first Trim Ring 7 disconnect the negative terminal of the battery and wait two minutes for the system ca
18. ions Modifications to any of the components ge anr sarnaaukla Gh ata gb ee cg AE ete gk ge Pa a EE a Ps eee Ply lt a AawntacA an RAG Raw Ree Rete Ahk Awe Shwe eee KA aaa 4A AAs ler a eee ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 17 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 09 19 13 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 10 Heat shrink the soldered connections made in the previous step Installation 1 Mount the control module in a secure place under the vehicle not in direct contact with any hot objects Our recommended mounting location can be seen in the pictures below The wiring harness is long enough to reach all connectors if installed in the recommended place 2 Jeep JK We recommend drilling the holes into the gas tank skid plate as shown in Figure 7 To protect the gas tank when drilling through the plate it is strongly recommended to place a piece of scrap metal between the gas tank and the skid plate Do not forget to remove the scrap metal when done Jeep TJ We recommend mounting it to the locker solenoid mounting plate See Figure 2 3 Bolt the RubiCrawler Control Module into place using the two 8 32 Socket Head Cap Screws and the 8 32 Nylon Locking Nuts 4 Plug in the connectors from the RubiCrawler Control Module to the RubiCrawler the transfer case the wiring harness connec
19. it without RTV to make sure the RubiCrawler flange face touches the transmission face completely This is to insure that the output shaftis not too long The product was designed for a standard output shaft stick out but the stick out could vary which would cause a major problem If you experience a problem DO NOT proceed call Advance Adapters Steps 3 and 4 are time sensitive and should be completed in under 10 minutes Figure 16 RubiCrawler Reclean the transmission face and the front face of the RubiCrawler using Installed solvent Apply an 1 8 bead of the supplied Chrysler ATF 4 compatible RTV tothe RubiCrawler as shownin Figure 15 Reinstall the O ring as shown in Figure 15 This is very important for the RubiCrawler and Transmission lubrication circuits Lift the RubiCrawler into place rotate the output shaft until the splines line up and the RubiCrawler slides on make sure it slides on by hand far enough to squish the RTV Fasten the RubiCrawler with the 10 supplied 10mm socket head cap screws using an 8 mm hex bit socket and the 10mm button head cap screw that bolts on under the shifter box using a6 mm hex bit socket Torque all bolts to 40 ft lbs See Figure 16 Figure 17 Install Supplied Install the supplied RubiCrawler foot mountusing the supplied 10 mm hex Foot Mount 10mm Hex Bolts And Washers SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions
20. l Module a hs a Bolt installation instructions athis time RubiCrawler Shift Cable Installation 1 Remove the 5 8 lock nuts and the 1 4 28 nutfromthein cab HA Py non bracketed end of the 4 supplied RubiCrawler shift g a cable and push it through the NY gt x pan D Tgr C pie ase Shifter Bracket newly cut slitin the floor grommet making sure the cable is routed to the passenger side ofthe stock cable ny O rg as 2 Route the cable as seen in the mii _ A illustrations below See Figure 19 Cable Routing Under Figure 19 Transmission Cooler Lines Stock Rotation Figure 20 Transfer Case Clocking Rotation 3 Boltthe RubiCrawler shifter bracket to the side ofthe RubiCrawler with the supplied 8 mm socket head cap screws and 1 4 washers using a6 mm Allen wrench See Figure 18 4 Verify thatthe RubiCrawler shift cable travels 1 8 past the heim joint stud for both high and low positions Boltthe heim joint to the lever using medium strength thread locking compound and the supplied 1 4 28 BHCS See Figure 21 SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for
21. le the stability control ESC The control module will also communicate with an AeroForce gauge sold separately which will display the current shift state of the RubiCrawler Preparing the Wiring NOTE If installing a RubiCrawler simultaneously start here when the transfer case is removed for ease of installation If the RubiCrawler has been previously installed you can still install this at any time NOTE Pictures of connectors and the position switch can be found on the last page along with a wiring schematic 1 Unplug the connector from the transfer case position switch if the transfer case is still in the vehicle 2 Cut the connector off the wiring harness with about 3 of wire left on the connector 3 Make sure that there is a piece of 1 4 heat shrink over both wires and then one piece of heat shrink over each wire that was just cut off 4 The Module is used for several applications and you will be required to cut one of the male plug off the module The plug that has the orange and brown wires connected need to be cut and wires striped pull back the wire loom You can use a piece of tape to hold the wire loom away from the end of the wires so you can solder 5 Solder the T case position plug to the orange and brown wires from the RubiCrawler control module Polarity does not matter 6 Heat shrink the soldered connections with the heat shrink placed over the individual wires in step 3 7 Remove the tape from the wire loom a
22. nd feed it into the heat shrink that is over both wires Ifthe wire loom is too long use some side cuiters to shorten the wire loom Once the wire loom Is fed into the heat shrink heat up the heat shrink sealing the wire loom into place 8 Make sure there Is a piece of heat shrink on each wire of the loose two wire Delphi connector that came with the control module 9 Solder the loose two wire Delphi connector to the previously cut two wires in the vehicle wiring harness See the chart below for vehicle specific wiring Control Module fi 03 O4 TJ 05 06 TJ 07 10 JK JE Eeen Dark Green Dark Blue Yellow Yellow Light Green SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of convers
23. pacitors to drain Next disconnect the two electrical connectors below the seat and then the seat can be removed Refer to the service manual for more informa Figure 8 Trim Ring SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 6 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 tion onremoving the seat 2 Remove the four T30 Torx bolts on the sides of the console 2 on the driver s side and 2 on the passenger side See Figure 7 3 Remove the transmission shifter knob Begin by grabbing the trim ring at the base of the shift knob and gently pull down while twisting it Remo
24. peration of the RubiCrawler refer to the Shifting Procedure Warranty paper work and the yellow tag attached to the RubiCrawler case SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 13 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 2 3 11 SHIFTING INSTRUCTIONS Transfer Case Shifting The transfer case can be shifted from two wheel drive to 4 wheel drive HIGH while the vehicle is moving To shift the transfer case into four wheel drive LOW you must shift the transmission to neutral and the vehicle speed must be below 2 mph The transfer case can be shifted at a complete stop but it is easier to shift the unit when at a very slow roll RubiCrawler Shifting
25. ponents We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 2 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 06 28 11 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 These are the bottom 12 items listed under the shifter kit components on the first page These items do need to be assembled The Igus bushings must be pressed into the shift handles An arbor press or a light hand with a hammer works well Once the bushings are installed the pivot pin gets installed through the handles with the wave washer between them p Install the handles into the bracket housing and install the bolt to secure the assembly in place use the retainer clip to hold in place SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the a
26. rn privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 12 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 into highrange This will grant access to insert the 1 4 28 x 5 8 button head bolt through the heim joint threading into RubiCrawler shiftlever See Figure 29 10 Tighten 5 8 jam nutagainst cable barrel 11 Refertothe disassembly instructions to reinstall the console dash panels and seat 12 Attach the transfer case knob mount to the drivers side lever with the supplied 1 4 28 x 5 8 flathead bolts Use medium Figure 29 Install Heim Joint to strength Loctite and torque to 10 ft lbs Snap factory RubiCrawler Shift Lever plastic knob to the knob mount 13 Attach the RubiCrawler knob mountto the passenger side shift lever also with 1 4 28x 5 8 flathead bolts Use medi
27. ssembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 3 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 6 28 11 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 Tool List 1 FULL SET OF HAND TOOLS INCLUDING 6 mm ALLEN WRENCH 16 mm DEEP SOCKET 8mm HEX BIT SOCKET 3 8 DRIVE RATCHET 15 16 WRENCH 5 32 ALLEN WRENCH 2 3 8 TORQUE WRENCH 25 TO 40 FT LBS REQUIRED 3 GASKET SCRAPER SMALL BRASS WIRE BRUSH 5 CLEANING SOLVENT PAINT THINNER ACETONE MEK ETC DO NOT USE DEGREASERS LIKE SIMPLE GREEN 6 STUBBY 9 16 WRENCH REQUIRED RATCHETING RECOMMENDED 7 T20 T30 AND T45 TORX BIT SOCKETS 8 SLIDE HAMMER Note on new installations if the transfer case is re clocked up closer to the floor board we have had customers complain of vibrations in the drivetrain Clocking the transfer case changes the driveline angles which creates a vibration and most think it is because of the new RubiCrawler Re clocking the transfer case from stock will require axle pinion angle adjustments INTRODUCTION The RubiCrawler is a two speed crawl box for Jeep Wranglers TJs and JKs from 2003 2
28. ssible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 7 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 13 14 RubiCrawler Install l 6 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 to avoid breaking the plastic rod end See Figure 12 Remove the shift housing from the shift cable by un clipping the plastic cable mount and sliding it out See Figure 13 Pull shiftcable grommetdown through floor and cuta slit to allow RubiCrawler cable to pass through on the passenger side Note cable will be in stalled in a later step Remove Red Plug Figure 14 Plug O ring location Remove the red plug and O ring from the RubiCrawler as seen in Figure 14 Remove the rag from the transmission and discard the red plug The RubiCrawler should be test fit into the vehicle by installing
29. the sales department can assist you Warranty will be voided if the proper transmission fluid levels are not maintained if any transmission fluid other than ATF 4 is used or the product has not been properly installed and instructions have not been followed SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI JKA P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 15 of 18 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 09 19 13 RUBICRAWLER CRAWL BOX JEEP WRANGLER JK 2007 2011 KIT CONSISTS OF No Qty Part No Description L l 42R800 CONTROL MODULE KIT KITINCLUDES 2 8 32 SOCKET HEAD CAP SCREWS 2 8 32 NYLON LOCK NUTS 5 1 4 x1 HEAT SHRINK l 3 WIRE DELPHI CONNECTOR l 2 WIRE DELPHI CONNECTOR 10 CAB
30. um strength Loctite and torque to 10 ft lbs Thread the 1 2 13 jam nut and Rubi Crawler knob onto knob mount tighten in correct orientation Transmission Fluid Re Fill Caution under filling or over filling can resultin damage to your transmission Only use Mopar approved ATF 4 to refill the transmission Park on a flat surface and apply parking brake Start the engine and let the vehicle idle 3 Apply the brakes and shift the transmission through all of the gears then back to NEUTRAL and leave the vehicleidling 4 Checkthetransmission fluid level with the dipstick Using aclean funnel add ATF 4 transmission fluid until the oil levelis between the two holes marked COLD Check to see if the transmission fluid level on the dipstick is even on both sides If one side is noticeably higher than the other the dipstick has picked up some fluid from the fill tube Allow the fluid to drain down the transmission fill tube and recheck 5 Now thatthe fluid level has been approximately achieved drive the vehicle 5 10 miles making sure to manually shiftthe transmission through all gears 6 Recheck the fluid level with the transmission at operating temperature vehicle idling on flat ground the parking brake set and the transmission in neutral Add ATF 4 to raise the fluid level to a point between the two holes marked HOT Do this slowly so that the transmission fill tube has time to drain and gives accurate readings NOTE For proper o
31. ve the Torx bolt witha T20 bit The transmission shift knob can now be removed from the lever See Figure 8 4 Removethetransfer case shiftknob You must grab firmly and pull straight up until it pops off A glove is recommended to protect your hand during this step as the removal can sometimes be difficult 5 Pull parking brake as far up as it will go 6 Remove the lower dash panel by prying witha small flathead screw driver at the top of the panel until it pops loose and then slide it out See Figure 9 7 Remove upper console by pulling up gently on the rear of it It is held on with metal clips that will pop out as itis lifted up and removed See Figure 10 8 Remove the lower console 9 Remove the transfer case shifter housing top cover See Figure 11 10 Remove the 4 mounting nuts that hold down the shifter Figure 10 Removing Upper Console housing with a 10mm socket Save these nuts as they will be reused 11 Turnthe transfer case shifter housing on its side 12 Carefully remove the shifter rod end from the pin using 2 flat head screw drivers Great care must be taken Rod End Pe Transfer case shift piii topscover L Figure 13 Transfer Figure 12 Rod End Removal Case Shift Housing Figure 11 Remove Shift Cable from Housing SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any po
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