Rubicon Express RE6500 User Manual
RUBICON EXPRESS. 3290 MONIER CIR. RANCHO CORDOVA, CA. 95742 916-473-4600
INSTALLATION INSTRUCTIONS FOR:
RE6500 MJ 5.5” SUSPENSION SYSTEM
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:
RE1141 Gen2 sway bar disconnects
RE1334 Coil spring spacers
RE1345 Front coil springs
RE1380 Front bump stop extensions
RE1513 Rear brake hose
RE1550 Front brake hoses
RE1660 XD adjustable track bar
RE1665 XD track bar bracket
RE1935 Rear spring perches
RE2025 Rear weld on shock mounts (pair)
RE2055 SOA spring plate x 2
RE2120 T-case lowering kit
RE2421 U-bolt kit , D35
RE3700 Lower front control arms
RE3780 Upper front Adjustable control arms
RE9900 Control arm drop brackets
RE9921 Sway bar relocation brackets
REQUIRED TOOLS:
Basic mechanics' hand tools
Jack stands and floor jack
Drill motor and 5/8” drill bit.
Pickle fork for track bar removal
Spring compressors
Brake fluid
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
be purchased at your local auto parts store.
as needed. Silicone base grease can
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.
INSTALLATION:
Note: Read all instructions before beginning installation. Lift heights
taller than 4.5” will require modifications to the rear driveshaft. A CVtype driveshaft and transfer case slip yoke eliminator are recommended.
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; it may be helpful to disconnect steering
linkage at pitman arm.
6. Remove front spring retainer clamps at bottom spring cup.
7. Remove front springs. Spring compressors may be helpful.
8. Support the front axle with jack stands.
9. Remove factory brake lines and replace with supplied stainless steel
lines. Some require positioning the block and line vertically at the
caliper. Watch line routing, use angle brackets and e-clips.
10. Remove the factory control arms that are to be replaced.
11. See instructions for installation of RE9900 control arm drop
brackets. Install now before proceeding.
12. Install the lower control arms with the rubber bushing at the drop
brackets. Super-flex assembly bolts to axle bracket with supplied
hardware. The offset tube is to be located as low as possible (zerk
on top – SEE PHOTO 1).
13. Install the new upper front adjustable control arms using supplied
hardware at axle end and factory bolt at frame end (don’t fully
tighten until vehicle is back on the ground). Set both control arms
to an initial length of 15 3/8” center to center. Further adjustment
may be needed at time of alignment for caster angle.
14. The 2” bump stop extension is to be located at the axle side spring
cup. Drill a 5/16 hole in center of cup and tap hole with supplied
self-threading bolt. This assembly will not be installed until after
springs are in place. Temporarily attach (use wire ore tape) bump
stop inside coil while installing springs. Bolt in place when possible
(after coils are installed).
15. Remove front bump stops from bottom of bump stop tower.
16. Remove coil spring isolators.
17. Install RE1334 coil spring spacers (SEE PHOTO 2).
18. Reinstall coil spring isolators and bump stops.
19. Install springs, use compressor or lever bar using caution, index
spring into lower spring cup. Caution! Coil springs have high
potential energy, which can cause injury.
20. In isolated cases the spring will rub the front of the bump stop
tower. If your spring rubs the bump stop tower you will need to
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install a lower profile bump stop. You can also cut bend and re-weld
the tower for extra clearance.
21. Install the spring retainer removed in #6. Use caution, this bolt
strips easily.
22. Install longer front shocks. Some require bar pins to be installed
through the bottom shock eyes (use light grease).
23. Install adjustable front track bar and bracket per instructions
supplied with them. Do not attach adjustable side until weight is on
vehicle and axle is centered.
24. Install sway bar quick disconnects per instructions supplied with
disconnects.
25. Torque all bolts to factory specs and double check your work.
-REAR AXLE-
26. Remove the rear shocks.
27. Support the rear of the vehicle by the frame.
28. Remove rear brake line and install supplied extended rear brake
line. Use line wrenches to avoid rounding off fittings. Tighten brake
line fittings before bleeding brakes.
29. Remove the u-bolts.
30. Support the axle and remove the springs.
31. Weld on new spring perches on top of axle housing (SEE PHOTO 3):
32. Install rear springs on top of axle using supplied spring plates.
33. Install tires and lower vehicle to ground.
34. Weld on shock mounts so new longer shocks will have about an
35. If installing RE2120 transfer case drop kit (see troubleshooting)
36. Adjust front track bar to center front axle per instructions supplied
37. Thoroughly bleed brake lines and check for leaks.
38. Double-check all nuts and bolts.
39. Test drive and note location of steering wheel.
40. Adjust drag link to center steering wheel.
41. Align vehicle as soon as is practical.
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 rear perches so pinion rises 2 degrees from stock for
standard driveshafts. Approximately 6-7 degrees for
CV driveshafts.
E. Make sure angles are proper and perches are aligned
before welding.
F. Weld perches using caution not to use excessive heat
while still maintaining good penetration.
G. Paint new perches.
Torque u-bolts to factory specs.
inch of travel left when the bump stops bottom out.
install it now. Support cross member with floor jack. The cross
member is factory mounted with two studs and two bolts. The studs
will have to be removed with a stud remover or by double nutting
them and backing them out. Lower the cross member just enough
to insert the spacers at each bolt hole and install bolts and washers.
with track bar.
42. Set caster to factory minimum, set toe in at factory maximum.
< FRAME END (RUBBER) - PHOTO 1
- AXLE END (ZERK ON TOP) >
PHOTO 2
PHOTO 3
TROUBLESHOOTING
DRIVELINE:
Acceleration vibration: caused by the pinion being too high in relation to
the transfer case output shaft. Install axle shims to bring pinion down.
Deceleration vibration: Caused by the pinion being too low in relation to
the transfer case output shaft. Install axle shims to bring pinion up.
Slip yoke vibration: Caused by excessive wear on the transfer case slip
yoke. (Very common on lifted vehicles with more than 30,000 miles).
To correct, install a slip yoke eliminator (SYE) kit and replacement
driveshaft, or CV driveshaft. Note that if an SYE is used, the transfer case
drop can usually be removed.
Driveshaft bind: Condition of interference between slip yoke and tube
yoke. Installing a high travel slip yoke may remedy (part# RE1822), or
install SYE and replacement driveshaft, or CV driveshaft. Note that if an
SYE is used, the transfer case drop can usually be removed.
HIGH SPEED WOBBLE:
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 caster will eliminate this condition.
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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