Rubicon Express RE6500 - Manual (Page 2)

install a lower profile bump stop. You can also cut bend and re-weld
the tower for extra clearance.
21. Install the spring retainer removed in #6. Use caution, this bolt
strips easily.
22. Install longer front shocks. Some require bar pins to be installed
through the bottom shock eyes (use light grease).
23. Install adjustable front track bar and bracket per instructions
supplied with them. Do not attach adjustable side until weight is on
vehicle and axle is centered.
24. Install sway bar quick disconnects per instructions supplied with
disconnects.
25. Torque all bolts to factory specs and double check your work.
-REAR AXLE-
26. Remove the rear shocks.
27. Support the rear of the vehicle by the frame.
28. Remove rear brake line and install supplied extended rear brake
line. Use line wrenches to avoid rounding off fittings. Tighten brake
line fittings before bleeding brakes.
29. Remove the u-bolts.
30. Support the axle and remove the springs.
31. Weld on new spring perches on top of axle housing (SEE PHOTO 3):
A. Remove paint on areas to be welded
B. Set width to match factory spring location.
C. Tack perches in place before final welding.
D. Set rear perches so pinion rises 2 degrees from stock for
standard driveshafts. Approximately 6-7 degrees for
CV driveshafts.
E. Make sure angles are proper and perches are aligned
before welding.
F. Weld perches using caution not to use excessive heat
while still maintaining good penetration.
G. Paint new perches.
32. Install rear springs on top of axle using supplied spring plates.
Torque u-bolts to factory specs.
33. Install tires and lower vehicle to ground.
34. Weld on shock mounts so new longer shocks will have about an
inch of travel left when the bump stops bottom out.
35. If installing RE2120 transfer case drop kit (see troubleshooting)
install it now. Support cross member with floor jack. The cross
member is factory mounted with two studs and two bolts. The studs
will have to be removed with a stud remover or by double nutting
them and backing them out. Lower the cross member just enough
to insert the spacers at each bolt hole and install bolts and washers.
36. Adjust front track bar to center front axle per instructions supplied
with track bar.
37. Thoroughly bleed brake lines and check for leaks.
38. Double-check all nuts and bolts.
39. Test drive and note location of steering wheel.
40. Adjust drag link to center steering wheel.
41. Align vehicle as soon as is practical.
42. Set caster to factory minimum, set toe in at factory maximum.
< FRAME END (RUBBER) - PHOTO 1 - AXLE END (ZERK ON TOP) >
PHOTO 2
PHOTO 3
TROUBLESHOOTING
DRIVELINE:
Acceleration vibration: caused by the pinion being too high in relation to
the transfer case output shaft. Install axle shims to bring pinion down.
Deceleration vibration: Caused by the pinion being too low in relation to
the transfer case output shaft. Install axle shims to bring pinion up.
Slip yoke vibration: Caused by excessive wear on the transfer case slip
yoke. (Very common on lifted vehicles with more than 30,000 miles).
To correct, install a slip yoke eliminator (SYE) kit and replacement
driveshaft, or CV driveshaft. Note that if an SYE is used, the transfer case
drop can usually be removed.
Driveshaft bind: Condition of interference between slip yoke and tube
yoke. Installing a high travel slip yoke may remedy (part# RE1822), or
install SYE and replacement driveshaft, or CV driveshaft. Note that if an
SYE is used, the transfer case drop can usually be removed.
HIGH SPEED WOBBLE:
A condition where front tires will shimmy after hitting a bump. Avoid bias
ply tires and wheels with excessive offset. Check for worn or loose parts.
In most cases a reduction of positive caster will eliminate this condition.
BUMP STEER:
Caused by improper relationship of drag link and track bar. To correct,
center axle again following the instructions supplied with the track bar.
Next determine the neutral position of the steering wheel. Adjust the
drag link to center the steering wheel.
RI6500 Page 2 of 2