Rubicon Express RE7000 - Manual

RUBICON EXPRESS 3290 MONIER CIR., RANCHO CORDOVA, CA. 95742 916-473-4600
INSTALLATION INSTRUCTIONS FOR:
RE7000 4.5” TJ/LJ SUPER-FLEX SUSPENSION SYSTEM
Safety Warning:
Suspension systems or components that enhance the off-road performance of your
vehicle may cause it to handle differently, on and off-road, than it did from the
factory. Care must be taken to prevent loss of control or vehicle rollover during
sudden maneuvers. Failure to drive the vehicle safely may result in serious injury
or death to driver and passengers. We recommend you always wear your seatbelt,
drive safely and avoid quick turns and other sudden maneuvers. Constant
maintenance is required to keep your vehicle safe. Thoroughly inspect your vehicle
before and after every off-road use.
Installation Warning:
We recommend that certified technicians perform the installations of our products.
Attempts to install these products without knowledge or experience may jeopardize
the safety of the vehicle. These instructions only cover the installation of our
products and may not include factory procedures for disassembly and reassembly
of factory components. Read instructions from start to finish and be sure all parts
are present before disassembling the vehicle. Included instructions are guidelines
only for recommended procedures and in no way are meant to be definitive.
Installer is responsible to insure a safe and controllable vehicle after performing
modifications. Do not perform test drives on public roads with partially completed
installations. Always double and triple check your work before use.
Note:
You may need to weld on new rear shock mounts (RE2035) or install
bolt-on shock relocators (RE2005) to prevent rear shocks from hitting
the spring cups.
KIT CONTENTS:
RE1155 Rear sway bar end links
RE1142 Gen2 sway bar disconnects
RE1355 Front coil springs
RE1360 Rear coil springs
RE1383 Front lower bump stop extensions
RE1385 Rear upper bump stop extensions
RE1553 Front brake lines
RE1600 Front adjustable track bar
RE1602 Rear track bar bracket (CV)
RE3700 (2) Ft & rr lower control arms
RE3780 Upper front control arms
RE3783 Upper rear control arms
REQUIRED TOOLS:
Basic mechanics' hand tools
Jack stands and floor jack
Spring compressors
Drill motor and drill bits (including 5/8”)
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:
Note: For lift heights over 3.5” a rear CV drive shaft is typically required
– see General Vibration in Troubleshooting before proceeding.
1. Raise vehicle and support with stands.
2. Remove wheels.
3. Remove front shocks.
4. Remove front sway bar end links.
5. Remove front spring retainer clamps.
6. Disconnect front track bar. Disconnecting steering at pitman arm
makes axle droop out farther.
7. Remove front coil springs. Spring compressors may be helpful.
8. Support the front axle with jack stands.
9. Remove all four factory control arms.
10. Remove factory brake lines and replace with supplied lines. Some
require positioning the block and line vertically at the caliper. Watch
line routing, use angle brackets and e-clips.
11. Drill 5/16” hole in center of lower coil spring pads.
12. Use self-tapping bolt through the front bump stop extension spacer
to cut threads in lower spring pad. Remove bolt and spacer, it will
be installed with the spring.
13. If so equipped, use factory eccentric hardware at front axle lower
arm mount. If not, use the supplied 9/16” bolt.
14. Install the lower control arms with the rubber bushing at the frame
bracket. Use the factory hardware at the bushing end (don’t fully
tighten until vehicle is back on the ground). The super-flex joint will
be installed at axle with offset tube being mounted as low as
possible (zerk on top - see Photo 1). Use supplied hardware for the
Superflex end.
15. Set upper front control arm length to ¼”-3/8” longer than stock for
a good starting point. Install the new upper control arms using
supplied hardware at axle end and factory hardware at frame end
(don’t fully tighten until vehicle is back on the ground).
16. Install the front coil springs (RE1355) with the pig-tail at the top
and the 3” bump stop extension inside of the coil. Coil spring
compressors may be useful. Once the coil spring is in place, thread
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