Rubicon Express RE6165 User Manual

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

INSTALLATION INSTRUCTIONS FOR:

RE6165 XJ CHEROKEE 2” SUSPENSION LIFT WITH BLOCKS.

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 RXT2421 Front shocks
2 RXT2210 Rear shocks
1 RE1334 Front coil spring spacer pair
1 RE1270 Rear lift block kit
1 RE1220 Rear u-bolt kit
1 RE1515 Rear brake hose

REQUIRED TOOLS:

Basic mechanic hand tools
Jack stands and floor jack
Spring compressor (optional)

INSTALLATION:

1. Support vehicle and remove wheels.

2. Remove old shocks.

3. Support the rear axle with jack stands.

4. Remove rear brake hose and install supplied stainless steel

rear brake line.

5. Remove the u-bolts.

6. Install rear block kit and new u-bolts with thick end of

block toward rear (see photo 1). Note that the hole in the
spring pad may need to be enlarged for the pin on the
block.

7. Remove and replace rear brake line.

8. Bleed brake system (rear only).

-FRONT AXLE-

9. Support front axle with jack stands.

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

11. If using spring compressor remove factory coils.

12. If a spring compressor is not being used disconnect sway

bar end links and track bar allowing axle to drop far enough
to remove factory coils.

13. Install coil spacer between frame and rubber spring isolator

(see photo 2). On some models factory bump stop and cup
may need to be removed to allow installation of spacer.

14. Install any previously removed parts.

15. Install shocks. The fronts require the supplied bar pins to be

installed through the bottom shock eyes (use light grease).
The rears require the supplied bar pins to be installed
through the top shock eyes (use light grease).

16. Torque all bolts to factory specs (or specs supplied with

parts) and double check your work.

17. Test drive and note location of steering wheel.

18. Adjust drag link to center steering wheel.

19. Align vehicle as soon as practical to minimum factory

caster and maximum factory toe-in specifications.

20. Retighten all bolts after 50 miles and again after every off

road excursion.

Photo 1

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Photo 2

LIFT KIT TROUBLESHOOTING

REAR DRIVELINE:

Acceleration vibration:

Caused by the pinion being too high in
relation to the transfer case output shaft. On leaf sprung
vehicles, install axle shims to lower pinion accordingly.

Deceleration vibration:

Caused by the pinion being too low in
relation to the transfer case output shaft. On leaf sprung
vehicles, install axle shims to raise pinion accordingly.

Slip yoke vibration:

Caused by excessive angle on the transfer
case slip yoke. Very common on vehicles with 2” or more of
lift. Lifts of 2”-3.5” can sometimes be cured with a transfer case
drop kit (pinion adjustment may also be required- see
acceleration and deceleration vibration troubleshooting above.

HIGH SPEED WOBBLE:

Fairly common with y-type steering on lifted XJ’s. 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 castor will
eliminate this condition. A good rule of thumb is minimum
factory caster and maximum factory toe in.

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.

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