Rubicon Express RE5015 User Manual

RUBICON EXPRESS 3290 MONIER CIR. RANCHO CORDOVA, CA. 95742 916-473-4600

INSTALLATION INSTRUCTIONS FOR:

RE5015 YJ SPRING-OVER KIT

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.

KIT CONTENTS:

RE2500 Drop pitman arm
RE1513 S.S. Front brake line kit
RE1555 S.S. Rear brake line
RE1920 Front spring perches
RE1930 Rear spring perches
RE2055 SOA spring plates x 4

REQUIRED TOOLS:

Basic mechanics hand tools
Jack stands and floor jacks
Pitman arm puller
Drill motor and bits
Welder
Grinder
Spray paint
Grease
Brake fluid

INSTALLATION:

Note: This is a spring over kit, not a complete conversion system,

and typically requires more components depending on budget and
desired out come. Since the kit requires accurate and sound welding of
spring perches, it is not recommended for the novice. This kit basically
moves the leaf spring perches to the top of the axle, markedly increasing
lift and flexibility. This arrangement can retain a stock-type ride quality
by retaining the original spring, however rear axle wrap and spring
longevity will be a problem. Other issues, like steering linkage,
driveshafts (a CV-type driveshaft is strongly recommended for this
application, shocks and bump stops will need to be addressed). Steering
will typically need an ‘S” link at the very least to clear the right front leaf
spring, or better yet a high steer system. Net lift from the conversion is
minimum 5.5-inches. For greater durability, and a total of 7-inches of lift,
we recommend running Rubicon RE1445 (rear) & RE1444 (front) 1.5”
Extreme-Duty Springs.

1. Before you begin, make certain you can safely support vehicle by the
frame and are working on a stable, level surface.

2. With vehicle supported remove wheels.

3. Front and rear axles will now need to be removed:

4. Weld on new spring perches – refer to Photo 1 for typical front:

A. Disconnect brake lines, E-brake cables and breather tube.
B. Disconnect shocks.
C. Remove rear track-bar. (will NOT be reinstalled)
D. Disconnect front track bar at axle.
E. Remove rear driveshaft.
F. Disconnect front driveshaft at pinion.
G. Disconnect front vacuum lines.
H. Disconnect drag link at pitman arm.
I. Remove U-bolts.
J. Remove leaf springs and lower axles.

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 front perches 4-5 degrees more positive than stock.

(pinion will rotate down)

E. Set rear perches so pinion rises approximately 8-9

degrees for CV driveshafts (recommended), or if you’re
attempting to use a longer factory type, 2.5 degrees from
stock for standard driveshafts.

F. Make sure angles are proper and perches are aligned

before welding.

G. Weld perches using caution not to use excessive heat

while still maintaining good penetration.

H. Paint new perches to prevent rusting.

Photo 1

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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.

12. Wheel alignment:

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.

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.

Photo 4

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