Rubicon Express RE7363 - Manual (Page 2)

RI73537363 Page 2 of 10
TYPICAL TOOLS REQUIRED
1. Basic mechanical hand tools
2. 1” & 1.25” bi-metal hole saws
3. ½” drill motor & drill bits
4. angle drill (for tight locations)
5. angle grinder
6. welder
7. plasma cutter, or reciprocating saw w/metal cutting blades, or cutting wheels for angle or die grinder (to
remove control arm mounts)
PRE INSTALLATION NOTE:
Control arm bushings are pre-lubed during initial assembly at Rubicon Express. As general maintenance the control arm bushings should be
lubed with a silicone base grease as needed. Silicone base grease can be purchased at your local auto parts store.
The Super-flex joints are also pre-lubed during initial assembly at Rubicon Express. As general maintenance the super-flex joints should be
greased as needed and the outer spanner nut tightened on the joint. Any type of grease will work on the Super-flex joints. Spanner nut
tools are available through Rubicon Express (RE3771 & RE3772) if needed for tightening of the joints.
INSTALLATION OVERVIEW
The installation process can be broken down into the following tasks:
1. Vehicle preparation for suspension installation
2. Installation of 3 piece cross member assembly
3. Installation of front control arms, track bar, coil springs and bump stops, shocks, and brake lines, Sway bar discos
4. Installation of rear control arm brackets
5. Installation of rear control arms, track bar bracket, bump stops, coil springs, shocks, brake lines, and sway bar links
6. Final detailing and adjustments.
Step 1 – Vehicle preparation
Prepare the vehicle for the suspension installation by removing the following parts from the vehicle. The transfer case
skid plate (4 Door models), fuel tank and exhaust will be re-installed at the end of the installation.
1. Automatic transmission skid plate (if equipped)
2. Transfer case skid plate (not re-installed on 4 door models)
3. Front and rear drive shafts
4. Fuel tank.
5. Exhaust, from the collector at the cross member to the muffler
NOTE: 2 Door JK’s will also require that the exhaust hanger just behind the head pipe to tail pipe connection
and the nut plate welded into the bottom of the frame on the drivers side for the t-case skid be removed
for proper fitment of the drivers side rear control arm brackets.
FUEL TANK REMOVALL: The fuel tank removal should be done when there is 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.
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.
Step 2 – Three Piece cross member installation.
A. Prepare the new cross member, RE4521, by loosely installing the supplied ½” bolts thru all 3 pieces before trying to install into
the vehicle. The shorter of the two ½” bolts install from the front to the back and the longer of the two from the back to the
front. Install the 4, 3/8” flat head bolts into the bottom of the cross member and tighten, then tighten the prior installed ½” bolts
and torque to 80 ft/lbs. Installing the hardware in this fashion will allow the removal of the center cross member section without
removal of the front lower control arms should transmission service become necessary. (photo 1)
B. Support the transmission/transfer case assembly at the rear output shaft.
C. Remove the 3 transmission mount nuts and gently lift the transmission/transfer case assembly to relive the weight off the factory
cross member. Remove the 4 cross member thru bolts and remove the factory cross member. (photo 2)
D. Install the left and right cross member brace’s using the supplied ½” bolt, washer, and nut strip. The nut strip is placed thru the
square hole just forward of the cross member, install hardware and loosely tighten. (Photo 3)