Rubicon Express RE7200 SERIES - Manual (Page 6)

Photo 11 Photo 12
C. FRONT BUMP STOPS - Drill 5/16” hole in center of lower spring pads. Use self-tapping bolt through bump stop to cut threads in
lower spring pad. Remove bolt and spacer, it will be installed with the spring.
D. FRONT COILS - Install the front coils with the bump stop inside of the coil – refer to Photo 12. Coil spring compressors may be
useful. Once the spring is in place, put the bolt through the bump stop extension and thread the bolt into the lower spring pad
(careful these strip easily). Be sure to rotate the coil to index the spring with lower coil cup, and reinstall coil spring clamp if
removed earlier (not all vehicles have the spring clamps).
Step 5 – Track bars and sway bar links
A. REAR TRACK BAR BRACKET – Remove the plastic dust shield that covers the bolt securing the rear track bar to the mount on the
axle housing and discard. Remove the Torx head bolt (T55) and disconnect axle end of track bar. Install track bar bracket using
the supplied ½” bolt and spacer (the spacer goes in the location vacated by the track bar to prevent the bracket from deforming
when the bolt is tightened - see photo 3 for similar installation). With the track bar bracket in place, drill two 5/16” holes in the
axle mount where the plastic dust shield was previously located, one on top and one on angled surface. Install the 5/16”
hardware in the holes drilled. If required, use supplied horseshoe shim to take up space between bracket and axle mount at top
5/16” bolt.
B. REAR TRACK BAR - Install the poly-bushing end of the new track bar at the frame. The bar should start out horizontal then turn
down toward the axle bracket. Mount the Heim end of the track bar in the track bar bracket using the Torx bolt removed earlier –
refer to Photo 13. Be sure the reducer bushing and two misalignment spacers are used (small end of spacers go up against
Heim). It may be easier to do this later when vehicle is back on its wheels.
Photo 13
C. FRONT TRACK BAR/BRACKET – drill out factory bracket to 5/8” with a high quality bit and some cutting fluid (or similar). If using
the RE1600 track bar skip to step ‘D’. If installing the RE1611 drop bracket for the RE1610 track bar, attach drop bracket with
supplied 5/8” hardware to the factory one so the new bracket slides up each side of the frame rail. Drill ½” holes through the
frame at the two holes in the new bracket being sure holes are perpendicular to the frame. Attach new bracket to the frame with
supplied ½” hardware - Refer to Photo 14.
D. FRONT TRACK BAR - Attach new track bar to lower mounting bracket (axle side) using factory hardware. This will be the poly-
bushing end of bar. Position bar so it starts out parallel with the axle (horizontal), then turns up toward the frame bracket. Before
connecting bar to upper mount, center the vehicle over the axle by measuring the distance from front fender flare to tire on both
driver and passenger sides of the vehicle, then adjusting vehicle until body is centered over the axle. The easiest way to
accomplish this is when the vehicle is back on its wheels, have an assistant turn steering wheel left or right as necessary. Adjust
spherical bearing end so that it will fit directly into the upper mount with the body centered. Tighten the jam nut to prevent the
spherical bearing end from moving on the threads. Use supplied 10mm hardware to attach RE1610 to new bracket, or supplied
5/8” hardware to attach RE1600 bar to factory mount – refer to Photo 15 for typical installation.
RE7200G Page 6 of 8