Rubicon Express RE7002 User Manual

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

INSTALLATION INSTRUCTIONS FOR:

RE7002 3.5” TJ/LJ STANDARD 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:
It is necessary to remove the factory transmission skid plates from
the chassis after the suspension installation. Failure to do so will
result in a damaged front drive shaft.

KIT CONTENTS:

RE1145 Front sway bar end links
RE1155 Rear sway bar end links
RE1172 Disconnect adapters
RE1363 Front coil springs
RE1365 Rear coil springs
RE1380 Front bump stop extensions
RE1385 Rear bump stop extension
RE1603 Rear track bar bracket
RE2100 Transfer case drop kit

REQUIRED TOOLS:

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

INSTALLATION:

Note: For best performance, consider a rear CV drive shaft– 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. Drill 5/16” hole in center of lower spring pads.

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

11. Install the front springs (RE1363) with the pig tail at the top and
the 2” bump stop extension inside of the coil. Coil spring
compressors may be useful. Once the coil spring is in place, thread
the bump stop bolt into the lower spring pad (refer to step #10).
Rotate the coil to index the spring with lower coil cup.

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

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

14. Install sway bar quick disconnects adapters per instructions supplied
with adapters. Install new sway bar end links (see Photo 1 for
typical installation).

15. Re-drill front track bar axle bracket over toward drivers side ¾”,
center-to- center (or install optional adjustable front track bar).
Reconnect track bar at new hole.

-REAR AXLE-

16. Remove the rear shocks.

17. Remove the rear sway bar end links.

18. Support the rear axle.

19. Disconnect rear track bar at axle.

20. Remove the rear springs.

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

22. Remove the Torx head bolt (t55) and disconnect axle end of track
bar. If not done previously

23. 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 2 for
similar installation).

24. 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.

25. Install the 5/16” hardware in the holes drilled in step #24. If
required, use supplied horseshoe shim to take up space between
bracket and axle mount at top 5/16” bolt.

26. Install the track bar in the track bar bracket using the Torx bolt
removed in step #22. It may be easier to do this later with weight
on the vehicle.

27. If installing optional cam bolts, install per instructions included with
cam bolts (see General Vibration in Troubleshooting).

28. Remove the rubber insert from the rear bump stop. Remove the
bump stop cup. Place the 1-1/2" bump stop extension between the

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bump stop cup and the frame using the supplied longer metric
hardware.

29. Install springs. Spring compressors may be helpful.

30. Install replacement sway bar end links.

31. Install longer rear shocks.

32. 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. NOTE: If used on a vehicle with

a 6 speed manual transmission contact between the shifter
and body may occur in 2
will be necessary to remove the shift boot to verify for
clearance and possibly modify the body to allow a minimum
of 1/8” clearance between the shifter and the body.

33. Install all tires.

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

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

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

nd

, 4th, and Reverse. In this case it

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

excursion.

PHOTO 1

TROUBLESHOOTING

Rear driveline:

Acceleration vibration:
the transfer case output shaft. Adjust upper control arms or cam bolts
(both optional) to lower pinion accordingly.

Deceleration vibration:
the transfer case output shaft. Adjust upper control arms or cam bolts
(both optional) to raise pinion accordingly.

General vibration:
Very common on vehicles with 2” or more of lift. It is typically acceptable
to install the included transfer case drop kit and use a standard drive
shaft. Optional cam bolts (RE1475) allow some adjustment of pinion
angle and may be needed (see acceleration and deceleration vibration
troubleshooting above). For best performance, install optional upper
adjustable control arms (RE3783), a slip yoke eliminator (SYE) kit (or CV
yoke on RUBICON model) and CV drive shaft. Adjust pinion so it is 2
degrees below parallel with CV drive shaft (see acceleration and
deceleration vibration troubleshooting above).

can usually be omitted with a CV drive shaft.

High speed wobble:

This is fairly common with y-type steering on lifted TJ's. It is 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.
Note that lift heights increased with coil spacers (or taller coils) may
exhibit wobble that cannot be corrected with alignment.

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.

Caused by the pinion being too high in relation to

Caused by the pinion being too low in relation to

Caused by excessive angle on the rear drive shaft.

A transfer case drop kit

PHOTO 2

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