Rubicon Express RE6030 User Manual

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

INSTALLATION INSTRUCTIONS FOR:

RE6010 XJ 3.5” SUPER-FLEX SUSPENSION SYSTEM W/ ADD-A-LEAFS

RE6030 XJ 3.5” SUPER-FLEX SUSPENSION SYSTEM W/ LEAF SPRINGS

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.

RE6010 KIT CONTENTS: RE6030 KIT CONTENTS:

1 RE1140 Gen2 sway bar disconnects 1 RE1140 Gen2 sway bar disconnects
1 RE1300 Front coil spring, pair 1 RE1300 Front coil spring, pair
1 RE1380 Front 2” bump stop extension 1 RE1380 Front 2” bump stop extension
1 RE1410 Add-a-leaf pair 2 RE1463 3.5” leaf spring
2 RE1480 Spring clamp pair 1 RE1515 Rear stainless steel brake line
1 RE1482 5/16” center pin pair 1 RE2421 U-bolt kit (Dana 35/44) or RE1225 (Chrysler 8.25)
1 RE1515 Rear stainless steel brake line 1 RE3700 Lower front fixed SF2control arms, pair
1 RE3700 Lower front fixed SF2 control arms, pair

REQUIRED TOOLS:

Basic mechanics' hand tools
Jack stands and floor jack
Drill motor and drill bits
Spring compressors

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

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. A spanner nut tool is available through
Rubicon Express (RE3772) if needed for tightening of the joint.

as needed. Silicone base grease can be purchased at your local auto parts store.

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INSTALLATION:

Note: 1984-1986 vehicles may require modifications to the front drive shaft for proper installation. These vehicles use a double offset joint, while later

vehicles use a double cardan (spicer) style CV joint. The spicer CV joint may be retro fitted to the earlier veh ic les b y c hanging the transfer case output
yoke for the later model. Lift heights this tall may require modifications to the rear driveshaft - see troubleshooting. Installation time should be approx.
8 hours.

1. Raise vehicle and support with stands.

2. Remove wheels.

3. Remove front shocks.

4. Remove front sway bar end links.

5. Disconnect front track bar at axle end.

6. Disconnect steering linkage at pitman arm.

7. Remove front spring retainers (at bottom) and springs.

8. Support the front axle with jack stands.

9. Remove brake hose mounting screw from inner fender well and straighten z shaped bend to lower brake hose. Re-attach brake hose to inner
fender well. If you purchased optional stainless lines, do not relocate the hard lines. Simply remove and replace your factory lines with the
supplied lines.

10. Remove the factory lower control arms. These will be replaced.

11. Install the lower control arms with the rubber bushing at t he frame (use factory bolt at this end, and don’t fully tighten until vehicle is back on the
ground). The super-flex assembly bolts to axle bracket with supplied hardware. The offset tube is to be located as low as possible (see photo 1).

12. Install the front bump stop extensions by drilling a 5/16” hole in the center of the lower coil spring mount, then tigh tening the self-tapping bolt to
cut the threads. Next, remove the bump stop assem b ly and place it into the center of the coil spring.

13. Install the coil springs and retainers (do not over t ighten the retainer bolt - it strips easily) with the bump stop extension in the center.

14. Tighten the bump stop extension bolt.

15. Install longer front shocks. Some require bar pins to be installed through the bottom shock eyes (use light grease).

16. Install sway bar quick disconnects p er instructions supplied with disconnects (see photo 2).

17. Re-drill front track bar axle bracket over toward d r ivers side ¾”, center-to- center (or install optional adjustabl e front track bar). Reconnect track
bar at new hole.

18. Torque all bolts to factory specs. Double-check your work.

-REAR AXLE-

19. Remove the rear shocks.

20. Remove the rear sway bar (this will not be reused).

21. Support the rear axle.

22.

Remove rear brake line and install supplied extended rear brake line.

23. Remove the U-bolts and rear leaf springs.

24. Add-a-leaf kit: Loosen any spring alignment clamps. Use c-clamps to clamp spring pack on each side of center pin. Remove center pin. Use vise
grip pliers on center-pin head. Carefully remove c-clamp s. I nsert add-a-leaf into spring pack. Add-a-leaf will go into spring pack in such a way as
to maintain the pyramid shape of the spring pack (see p hoto 3). Insert new center bolt through the spring pack with the head on the same side as
the old one (spring perch side). Use c-clamps to assist tightening of center bolt. Tighten to 20 ft/lbs. Replace the spring alignment clamps.
Leaf spring kit: Install new rear springs with new U-bolts in the same manner as fac tory springs – SEE PHOTO 3-B (don’t fully tighten spring
eyebolts until vehicle is back on the ground). The 3/8” center pins are stronger than stock and usually require enlarging the spring pad hole. The
pins usually come with spacers installed for use w/ floating type degree shims (see troubleshooting for typical shimming requirements). If required,
remove spacers so pin does not bottom out on axle tube. If using steel Rubicon Express shims, remove the spacers and replace with the shims
(SEE PHOTO 4). These steel shims will require reaming to 3/8” for 3/8” pins.

25. Reinstall springs and u-bolts. Do not fully tighten spring eyebolts until vehicle is back on the ground.

26. Install longer rear shocks. Some require bar pins to be installed through the top shock eyes (use light grease).

27. Install tires.

28. Thoroughly bleed brake lines and check for leaks.

29. Torque all bolts to factory specs (or specs supplied with pa rt s) and double check your work.

30. Test drive and note location of steering wheel.

31. Adjust drag link to center steering wheel.

32. Align vehicle as soon as possible. We suggest Caster @ minimum setting and Toe @ Maximum setting per factory specs

33. Retighten all bolts after 50 miles and again after every of f-road excursion.

34. Reminder: Do not reinstall the rear sway bar; it will not be reused.

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