Rubicon Express RE7144 - Manual (Page 2)

RE7123B Page 2 of 6
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. Installation of front control arms, track bar and bracket, coil springs and bump stops, shocks, and brake lines, Sway bar
disconnects.
2. Installation of rear control arms, track bar bracket, bump stops, coil springs, shocks, brake lines, and sway bar links
3. Final detailing and adjustments.
Step 1 – Front arm and component installation
A. With the vehicle and axle properly supported prepare the front end suspension component installation by removing the following
items; shocks, sway bar links, and track bar. These items will not be reinstalled on the vehicle.
B. Remove the brake line attaching screw at the frame but keep the brake system sealed at this time. Unclip the abs wires from
there attaching points for additional length. Lower the breather hose clip on the shock tower approximately 4”.
C. Lower the axle and remove both coil springs.
Front arm Installation
A. Remove the passenger’s side factory upper and lower control arms.
NOTE: It will be necessary to cut the upper control arm bolt off at the frame end to remove the passenger upper
front arm. This is due to the bolt being installed from the inside out prior to the exhaust installation from the factory.
Alternatively the head pipe assembly can be removed to pull the bolt out of the frame bracket. If choosing to unbolt the
head pipe be sure to disconnect all O2 sensors before removal. (photo 1)
B. Set the upper arms to an initial setting of 18.75” center to center. With the supplied ½” bolt install the Super-Flex end of the arm
into the frame pocket for the upper control arm and the fork of the arm over the bushing mount on the axle. Use the factory
hardware thru the fork end of the arm.
C. Using the factory hardware install the lower arm into the frame pocket and the flex joint to the axle. The bend in the arm will be
towards the center of the vehicle allowing for proper tire clearance. Both arms need to have the zerk fittings facing up to avoid
trail damage.
D. Repeat steps A – C on the driver’s side.
E. Loosely assemble all hardware on the control arms. When the vehicle is back on the ground under its own weight torque upper
control arm bolts to 70ft/lbs and lower control arm bolts to 90 ft/lbs
NOTE: It will be necessary to re-adjust the upper arms during the final check to properly set the castor angle.