Rubicon Express RE5525 User Manual
Page 2
24
Remove u-bolts & spring plates.
25
Remove stock rear leaf springs.
26
Remove factory brake hose and replace with new stainless
line.
27
Lightly grease and install rear shackle and main spring eye
bushings. Small shackle bushings go to the frame and do not
use a steel sleeve. Main spring eyes use the steel sleeves
(9/16” id one at double wrap end). Rear shackles have
straight side plates and include a cross bar and bolt (see
photo 5).
28
Install rear shackles and springs into vehicle with double
wrap end at the frame (see photo 6). The center pins may
come with spacers installed for use w/ floating type degree
shims. Be sure pins do not bottom out on axle tube whether
using shims or not- remove spacers as required DO NOT
fully tighten the spring eye or shackle bolts at this time.
Bolts will be tightened to spec once the vehicle is on the
ground If using, insert 2.5” wide shim between spring and
spring pad on axle. Thicker end of shim should be at front
of vehicle (pinion points up).
29
(See photo 7 for typical installation of steps 30-31) install
new u-bolts and spring plates with shock studs. Torque u-
bolts to 65-80 ft/lbs, or u-bolt specs if supplied.
30
Install longer rear shocks.
31
Torque spring eye bolts. ½”: 65-80 ft/lbs. 9/16”: 75-90
ft/lbs.
32
If using, install transfer case drop 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.
33
Lower axle so that it is at full droop. Rotate the rear drive
shaft to insure the yokes do not bind. If binding occurs and
shims are properly installed, a CV yoke and CV drive shaft
are likely required.
34
Lower vehicle and tighten top shackle bolts (do not over
torque this will crush bushing).
35
Bleed brake system. Inspect all brake hoses and lines for
leaks, kinks or damage.
36
Grease all zerk fittings on new bushings.
37
Lengthen drag link to center steering wheel.
38
Recheck all bolts - use factory torque specs if not given.
Recheck after 50 miles and then after every off road
excursion.
PHOTO 1
< FRAME END (MILITARY WRAP) – PHOTO 2 – SHACKLE END >
PHOTO 3
PHOTO 4
RI5525 Page 2 of 3