Rubicon Express RE5515 User Manual

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

INSTALLATION INSTRUCTIONS FOR:

RE5515 4.0” YJ STANDARD LEAF SPRING LIFT 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:

2 RXT2410 Rear shocks
2 RXT2811 Front shocks
1 RE1180 Sway bar disconnect kit
4 RE1425 Leaf springs
1 RE1492 4 Leaf springs main eye bushing kit
1 RE1466 Degree shims, 2.5” x 4* aluminum
1 RE1505 Front brake line extension
1 RE1513 Rear brake line
1 RE1630 Front track bar bracket
1 RE2007 YJ rear shock relocator
1 RE2100 Transfer case drop kit 1”
1 RE2420 Front u-bolt kit
1 RE2421 Rear u-bolt kit

1

RE2500 Pitman Arm P/S

REQUIRED TOOLS:

Basic mechanics' tools
Drill and ½’ bit
Floor jack
Jack stands (2 pair)

INSTALLATION:

Note: For optimum rear driveline performance we recommend a

slip yoke eliminator kit and CV drive shaft be used with this lift
(see slip yoke vibration in “troubleshooting” before proceeding).

1 Block rear wheels of vehicle.
2 Raise front of vehicle and support frame with jack stands.
3 Remove front wheels.
4 Remove front shocks.
5 Remove axle end of front track bar.
6 Support axle with jack stands.
7 Remove u-bolts & spring plates.
8 Remove leaf springs.
9 Install new front brake line extensions.
10 Lightly grease front main spring eye bushings. Main spring

eyes use the 9/16” id steel sleeves at double military wrap
end.

11 Install leaf springs into vehicle with double military wrapped

end at the frame (see photo 1). The center pins may come
with spacers installed for use w/ floating type degree shims.
Be sure pins do not bottom out on axle tube whether using
shims or not- remove spacers if needed. Slightly snug bolts.
DO NOT fully tighten the spring eye or shackle bolts at this
time. Bolts will be tightened to spec once the vehicle is on
the ground (step 18).

12 (See photo 2 for typical installation of steps 12-14). Install

new u-bolts with old spring plates. Torque u-bolts to 65-80
ft/lbs, or u-bolt specs if supplied.

13 Use tie rod removal tool to remove drag link at pitman arm.

Use a puller to remove stock pitman arm. Install new drop

pitman arm and stock drag link
14 Install longer front shocks.
15 Install sway bar disconnects.
16 Install front tires.
17 Lower front of vehicle.
18 Torque spring eye and shackle bolts to factory specs.
19 Install axle end of front track bar with new bracket. Small

end of new bracket will fit into slot under factory mount (see

photo 3). Drill out old mounting hole to ½” and attach

bracket with supplied bolt. Attach track bar to top hole with

factory bolt.

-REAR AXLE-

20 Block front wheels of vehicle.
21 Raise rear of vehicle and support frame with jack stands.
22 Remove rear wheels.
23 Support rear axle with jack stands.
24 Remove shocks.
25 Remove rear track bar. This will not be reused.
26 Remove u-bolts & spring plates.
27 Remove stock rear leaf springs.
28 Remove factory rear brake hose and replace with new

stainless line.

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29 Lightly grease and install main spring eye bushings. Main

spring eyes use the 9/16” id steel sleeves at double military
wrap end.

30 Install new rear leaf springs into vehicle with double military

wrap end at the frame (ref. photo 1). The center pins may
come with spacers installed for use w/ floating type degree
shims. Be sure pins do not bottom out on axle tube whether
using shims or not- remove spacers as required. If using
steel Rubicon MFG’s shims, remove the spacers and replace
with the shims. These steel shims will require reaming to
3/8” for 3/8” pins.

31 If using, insert 4* wide shim between spring and spring pad

on axle. Thicker end of shim should be at front of vehicle
(pinion points up).

32 Slightly snug bolts. DO NOT fully tighten the spring eye or

shackle bolts at this time. Bolts will be tightened to spec
once the vehicle is on the ground (step 41).

33 Install new u-bolts with old spring plates. Torque u-bolts to

65-80 ft/lbs, or u-bolt specs if supplied.
34 Install longer rear shocks.
35 If using, install transfer case drop kit by supporting one side

of transfer case with floor jack. Remove hardware from one

side of cross member. Install spacers and new hardware.

Tighten to 55 ft/lbs. Repeat on opposite side.
36 Lower axle so it is at full droop. Rotate the rear drive shaft

to insure the yokes do not bind. If yokes bind and shims are

installed properly, a slip yoke eliminator and CV drive shaft

are likely required.
37 Lower rear of vehicle to ground.
38 Bleed brake system. Inspect all brake hoses and lines for

leaks, kinks or damage.
39 Grease all zerk fittings on new bushings.
40 Lengthen drag link to center steering wheel.
41 Recheck all bolts - use factory torque specs if not given.

Recheck after 50 miles and then after every off road

excursion.
42 Reminder: Do not reinstall the rear track bar; it will not be

reused.

PHOTO 2

< FRAME END (MILITARY WRAP) – PHOTO 1 – SHACKLE END >

PHOTO 3

REAR DRIVELINE:

Acceleration vibration:
to the transfer case output shaft. On leaf sprung vehicles, install axle
shims to lower pinion accordingly.

Deceleration vibration:
to the transfer case output shaft. On leaf sprung vehicles, install axle
shims to raise pinion accordingly.

Slip yoke vibration:
slip yoke. Very common on vehicles with 2” or more of lift. The transfer
case drop kit and shims provided may be an acceptable temporary fix
(pinion adjustment may also be required- see acceleration and
deceleration vibration troubleshooting above). If this is not acceptable,
a slip yoke eliminator and CV drive shaft is likely required and highly
recommended. Adjust pinion so it is 2 degrees below parallel with CV
drive shaft (see acceleration and deceleration vibration troubleshooting
above). Note that transfer case drop kits can usually be omitted when
using a CV drive shaft.

LIFT KIT TROUBLESHOOTING

Caused by the pinion being too high in relation

Caused by the pinion being too low in relation

Caused by excessive angle at the rear transfer case

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