Rubicon Express RE6330 User Manual

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

INSTALLATION INSTRUCTIONS FOR:

RE6330 XJ EXTREME DUTY LONG ARM UPGRADE

Congratulations on purchasing the ultimate control arm upgrade available for the front of the Jeep XJ Cherokee. This kit is
designed to upgrade our short control arm lifts in the 4.5” – 5.5” range. The kit includes the same extreme duty upper and
lower control arm design as the front of our famous TJ Long Arm System, plus an extreme duty crossmember specifically
designed for the XJ uni-frame.

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 seat belt, 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

RE4000 Front Lower Left Extreme Duty Control Arm w/ hardware
RE4010 Front Lower Right Extreme Duty Control Arm
RE4020 Front, pair Upper Extreme Duty Control Arms w/ hardware
RE9920 XJLA Crossmember Sides (Bo x 1 o f 2)
RE9922 XJLA Crossmember Center Section (Box 2 of 2)

TYPICAL TOOLS REQUIRED

1-1/8” hole saw for steel, ½” drill motor & drill bits, angle grinder,
Basic mechanical hand tools, several C-clamps or vise grips
Floor jack & jack stands (2 for the axle, one for the transfer case and another pair for the frame if not using a lift)
Plasma cutter, or reciprocating saw w/metal cutting blades and Mig Welder

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. Spanner nut
tools are available through Rubicon Express (RE3771 & RE3772) if needed for tightening of the joints.

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

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INSTALLATION OVERVIEW

The installation process can be broken down into the following tasks:

1. Removal of factory lower control arm mounts from uniframe.

2. Front 3- piece crossmember.

3. Control arms.

Step 1 - Removal of factory lower control arm mounts on frame.

First, support vehicle by uni-frame (preferably on a lift) and work on a stable level surface. Support axle with jack
stands and remove factory control arms. Be sure to keep the rear bolts from the upper arms and the front bolts
from the lower arms as they will be reused. It may be helpful to disconnect one end of the track bar to allow some
axle movement for aligning control arm bolts during assembly.

A. Cut off the factory lower control arm mounts from the uni-frame. Use extreme care as not to damage the

uniframe, or cut into existing brake, fuel, or electrical lines.

B. Grind rough areas smooth and repaint – refer to Photo 1 for typical bracket removal.

Photo 1

Photo 2

Step 2 - Front 3-piece crossmember

A. First, support transmission/transfer case and remove factory crossmember (and skid plate if there). Loosely bolt

transmission adapter plate to transmission mount so fitment can be checked with new crossmember in position.
The adapter should be positioned with the eight-hole surface up and off set to one side just like the factory
crossmember holes.

B. Note that the factory crossmember is held up by two bolts and two studs. The studs will have to be removed with a

stud remover tool or it may be possible to double nut them and back them out.

C. Refer to Photo 2 for a layout of the right side components of the “3-Piece Crossmember”. Generally align the

center slots of the crossmember over the center slots of the left and right control arm mounts and loosely bolt them
together (through the counter sunk holes in the crossmember into the PEM nut of the control arm mounts) with the
four supplied 1/2” flat head bolts. Loosely bolt assembly up into position with the four supplied 10mm bolts and
flat washers (early models use the front and middle slots and later models use the middle and rear slots) – refer to
Photo 3. Align control arm mounts so their nine holes can be transferred through the horizontal pinch welds along
the inside of the uni-frame rails and tighten the four 10mm and four ½” flat head bolts.

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