Rubicon Express RE7000 User Manual

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

INSTALLATION INSTRUCTIONS FOR:

RE7000 4.5” TJ/LJ SUPER-FLEX 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.

Note:
You may need to weld on new rear shock mounts (RE2035) or install
bolt-on shock relocators (RE2005) to prevent rear shocks from hitting
the spring cups.

KIT CONTENTS:

RE1155 Rear sway bar end links
RE1142 Gen2 sway bar disconnects
RE1355 Front coil springs
RE1360 Rear coil springs
RE1383 Front lower bump stop extensions
RE1385 Rear upper bump stop extensions
RE1553 Front brake lines
RE1600 Front adjustable track bar
RE1602 Rear track bar bracket (CV)
RE3700 (2) Ft & rr lower control arms
RE3780 Upper front control arms
RE3783 Upper rear control arms

REQUIRED TOOLS:

Basic mechanics' hand tools
Jack stands and floor jack
Spring compressors
Drill motor and drill bits (including 5/8”)

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.

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: For lift heights over 3.5” a rear CV drive shaft is typically required
– see General Vibration in Troubleshooting before proceeding.

1. Raise vehicle and support with stands.

2. Remove wheels.

3. Remove front shocks.

4. Remove front sway bar end links.

5. Remove front spring retainer clamps.

6. Disconnect front track bar. Disconnecting steering at pitman arm
makes axle droop out farther.

7. Remove front coil springs. Spring compressors may be helpful.

8. Support the front axle with jack stands.

9. Remove all four factory control arms.

10. Remove factory brake lines and replace with supplied lines. Some
require positioning the block and line vertically at the caliper. Watch
line routing, use angle brackets and e-clips.

11. Drill 5/16” hole in center of lower coil spring pads.

12. Use self-tapping bolt through the front bump stop extension spacer
to cut threads in lower spring pad. Remove bolt and spacer, it will
be installed with the spring.

13. If so equipped, use factory eccentric hardware at front axle lower
arm mount. If not, use the supplied 9/16” bolt.

14. Install the lower control arms with the rubber bushing at the frame
bracket. Use the factory hardware at the bushing end (don’t fully
tighten until vehicle is back on the ground). The super-flex joint will
be installed at axle with offset tube being mounted as low as
possible (zerk on top - see Photo 1). Use supplied hardware for the
Superflex end.

15. Set upper front control arm length to ¼”-3/8” longer than stock for
a good starting point. Install the new upper control arms using
supplied hardware at axle end and factory hardware at frame end
(don’t fully tighten until vehicle is back on the ground).

16. Install the front coil springs (RE1355) with the pig-tail at the top
and the 3” bump stop extension inside of the coil. Coil spring
compressors may be useful. Once the coil spring is in place, thread

as needed. Silicone base grease can

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the bump stop bolt into the lower spring pad (refer to step #12).
Rotate the coil to index the spring with lower coil cup.

17. Install the spring retainer clamp removed in step #5.

18. Install longer front shocks. Bar pins may need to be put through the
bottom shock eyes (use light grease).

19. Install adjustable front track bar per instructions supplied with track
bar. Make final adjustment when weight is on vehicle and axle is
centered.

20. Install sway bar quick disconnects per instructions supplied with
disconnects (see Photo 2 for typical installation).

-REAR AXLE-

21. Remove the rear shocks.

22. Remove the rear sway bar end links.

23. Support the rear axle.

24. Disconnect rear track bar at axle.

25. Remove all four factory control arms.

26. Remove the rear springs.

27. Remove the plastic dust shield that covers the bolt securing the rear
track bar to the mount on the axle housing and discard.

28. Remove the Torx head bolt (t55) and disconnect axle end of track
bar, if not done previously.

29. Install track bar bracket using the supplied ½” bolt and spacer (the
spacer goes in the location vacated by the track bar to prevent the
bracket from deforming when the bolt is tightened - see Photo 3 for
similar installation).

30. With the track bar bracket in place, drill two 5/16” holes in the axle
mount where the plastic dust shield was previously located, one on
top and one on angled surface.

31. Install the 5/16” hardware in the holes drilled in step #30.

32. Install the track bar in the track bar bracket using the Torx bolt
removed in step #28. It may be easier to do this later with weight
on the vehicle.

33. Install the lower control arms with the rubber bushing at the frame
and super flex end at the axle. The offset tube should be mounted
as low as possible (zerk on top - see Photo 1). Use the factory
hardware at the frame and the supplied bolt through the Superflex
joint at the axle mount (don’t fully tighten until vehicle is back on
the ground).

34. Set upper control arm length 3/4” longer than stock for a CV drive
shaft (1/4” if trying to use std shaft) as a good starting point (see
general vibration in troubleshooting). Install the upper control arms
using the factory hardware (don’t fully tighten until vehicle is back
on the ground). Super-Flex end should be at axle with zerk on top
(see Photo 4).

35. Remove the rubber insert from the rear bump stop. Remove the
bump stop cup. Place the 1-1/2" bump stop extension (RE1385)
between the bump stop cup and the frame using the supplied
longer metric hardware.

36. Install coil springs (RE1360). Spring compressors may be helpful.

37. Install replacement sway bar end links.

38. Install longer rear shocks.

39. If using, install transfer case drop kit by supporting one side of
transfer case with floor jack. Remove hardware from one side of
crossmember. Install spacers and new hardware. Tighten to 55
ft./lbs. Repeat on opposite side. NOT TO BE USED ON 6 SPEEDS

40. Install all tires.

41. Lower vehicle to ground and adjust front track bar to center front
axle per instructions supplied with track bar.

42. Thoroughly bleed brake lines and check for leaks.

43. Double-check all nuts and bolts to factory torque specs.

44. Test drive and note location of steering wheel. Adjust drag link to
center steering wheel.

45. Align vehicle as soon as practical. A good rule of thumb is minimum
factory caster and maximum factory toe-in.

46. Recheck all bolts after 50 miles and again after every off road

excursion.

< FRAME END (RUBBER) - PHOTO 1 –AXLE END (ZERK ON TOP) >

PHOTO 2

PHOTO 3

<FRAME END – PHOTO 4 - AXLE END (ZERK ON TOP) >

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