Rubicon Express RE5015 - Manual (Page 2)

6. Install leaf springs – refer to Photo 3 for typical front:
A. Remember to grease all bushings.
B. Place leaf springs on top of axles and bolt to
factory shackles and spring hangers.
C. Put spring plates on top of springs.
D. Raise up axles into place and install u-bolts (we
recommend using new u-bolts).
E. Use factory torque specs for all u-bolts and spring bolts.
Photo 3
7. Install longer front and rear shocks
8. Install brake lines:
A. Install lines with banjo fittings on front calipers.
B. Install supplied anchor bracket to frame to secure upper
mount. Use E-clips and self-tapping screws.
C. Install rear line in the same fashion as the stock line.
D. Bleed entire brake system with D.O.T 3 fluid or better.
9. Relocate emergency brake cables (stock to 1.5” springs):
A. Route passenger side cable over spring and through
rubber muffler mount. Abandon clamp to body.
B. Route driver side over spring and to lowest portion of
factory frame mount. Drill a new ½”hole to receive
housing end. Readjust cable tension.
10. Install rear driveshaft:
A. Install slip yoke eliminator kit and new CV driveshaft
according to instructions enclosed with those products.
B. If attempting to use factory driveshaft, have shaft
lengthened and rebalanced by a competent shop.
C. On ‘94-95 models we recommend switching pinion yokes
to the 1310 series to gain ¾” drive line length. Always
use fresh yoke straps and keep u-joints greased.
11. Install pitman arm- refer to Photo 4:
A. Use pitman arm puller to remove pitman arm. Do not
attempt to remove pitman arm with a hammer or torch!
B. Install supplied drop pitman arm and torque to factory
spec.
Photo 4
12. Wheel alignment:
A. Typically no alignment is necessary other than centering
steering wheel
B. Rear track bar will not be reinstalled.
C. Depending on axle and suspension configuration, If you
are re-Installing a front track bar, you may need to
fabricate a track bar bracket or use RE1630 for a YJ D30.
13. Check all your work and check all bolts for tightness.
14. Install wheels and tires and lower vehicle.
15. Test drive and recheck bolts after the first 50 miles and after every
off-road excursion.
RI5015.doc Page 2 of 2