Rubicon Express RE5520 - Manual (Page 2)

25 Remove shocks.
26 Remove rear track bar. This will not be reused.
27 Remove u-bolts & spring plates.
28 Remove rear springs.
29 Remove factory brake hose and replace with stainless line.
30 Lightly grease and install rear shackle and main spring eye
bushings. Main spring eyes use the 9/16” id steel sleeves at
double military wrap end. Rear shackles have angled side
plates and do not include a cross bar and bolt (see photo 6).
31 Install rear shackles and springs into vehicle with double
military wrap end at the frame (see photo 7). The center
pins may come with spacers installed for use w/ floating type
degree shims. Be sure pins don’t bottom out on axle tube
whether using shims or not- remove spacers as required. Do
not fully tighten spring eye or shackle bolts at this time.
32 If using, insert 4* shim between spring and spring pad on
axle. Thicker end of shim should be at front of vehicle
(pinion points up).
33 Install new u-bolts with old spring plates. Torque u-bolts to
65-80 ft/lbs, or u-bolt specs if supplied.
34 Install longer rear shocks.
35 Torque spring eye and shackle bolts. ½”: 65-80 ft/lbs.
9/16”: 75-90 ft/lbs.
36 If using, install transfer case drop kit by supporting one side
of transfer case with floor jack. Remove hardware from one
side of cross member. Install spacers and new hardware.
Tighten to 55 ft/lbs. Repeat on opposite side.
37 Lower axle so that it is at full droop. Rotate the rear drive
shaft to insure the yokes do not bind. If yokes bind and
shims are installed properly, a slip yoke eliminator and CV
drive shaft are likely required.
38 Lower rear of vehicle.
39 Bleed brake system. Inspect all brake hoses and lines for
leaks, kinks or damage.
40 Grease all zerk fittings on new bushings.
41 Lengthen drag link to center steering wheel.
42 Recheck all bolts - use factory torque specs if not given.
Recheck after 50 miles and then after every off road
excursion.
43 Reminder: Do not reinstall the rear track bar; it will not be
reused.
PHOTO 1
< FRAME END (MILITARY WRAP) – PHOTO 2 – SHACKLE END >
PHOTO 3
PHOTO 4
RI5520 Page 2 of 3