Rubicon Express RE7200 SERIES - Manual (Page 4)

H. Use a 3/16” drill bit to run a pilot hole through both sides of frame at all six hole locations. Use care to drill perpendicular to
frame.
I.
Use 1” hole saw to enlarge the six pilot holes only on outside surface of frame rail, and use ½” drill bit to enlarge the six pilot
holes only on inside surface of frame rail opposite of 1” hole – refer to Photo 6.
Photo 6
J. Install six frame spacers into the holes you just drilled. We recommend welding the outside surface of spacer to the frame. If
welding, chamfered edge goes to outside of frame for weld fillet. Grind flush when finished. If not welding, chamfer goes inward.
Use ½” rod or bolt to align spacer with ½” hole in inside surface frame rail – refer to Photo 7. Repeat welding and grinding at the
remaining five spacers and paint all bare metal to protect it.
Photo 7
K. You are now ready to permanently install pan. A total of 10 bolts will be used through bottom of frame braces and crossmember,
and a total of 6 bolts will be used through side of frame braces and frame rails – refer to Photo 8. Install all remaining flat head
bolts at center section and bolt the transmission mounting plate to crossmember and factory transmission mount.
Photo 8
Step 3 – Control Arms
A. FRONT - Adjust front lower control arms’ length to an initial setting of 37.5” from bolt center to bolt center. Final arm lengths
seem to vary from around 37.5” to 38” depending on lift, axle squareness (see step C) and differential clearance to track bar.
Install adjustable end of arm to front crossmember with supplied hardware (zerk on top). Position the arms so the welded on
brackets for the front upper arms are on top and leaning toward each other.
RE7200G Page 4 of 8