Rubicon Express RE7142 User Manual

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

INSTALLATION INSTRUCTIONS FOR:

RE7122 2 DOOR JK WRANGLER
RE7142 4 DOOR JK WRANGLER

3.5” 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 dr ive 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:
All procedures described in these instructions were performed while the vehicle was properly supported on a vehicle lift. Use caution when
supporting the vehicle as removing and installing parts will change the vehicle center weight. Rubicon Express recommends that chassis support
jacks are always used at the front and rear of the vehicle during the installation of a suspension system.

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.

ESP WARNING NOTE: The new 2007 Jeep Wrangler JK is equipped an Electric Stability Program (ESP). This system is designed to help
control the vehicle in times of uncertain traction conditions and roll stability. Due to the complex nature of this program Rubicon Express
strongly suggest that after lifting the vehicle it is returned to the dealer for a computer “flash” to re address tire size and proper ESP control
settings. Rubicon Express also recommends that you become familiar with the ESP controls and how the different level of settings can help you to
keep better control of your vehicle.

WHEEL NOTICE: If using factory wheels it will be necessary to purchase 1.5” wheel spacers to provide proper clearance

to suspension components. Otherwise aftermarket wheels with 4.5” back space measurement will be required.

KIT CONTENTS

RE1157 Rear Sway Bar End Links
RE1370 (2 Door) RE1371 (4 Door) Front 3.5” Coil Springs
RE1375 (2 Door) RE1376 (4 Door) Rear 3.5” Coil Springs
RE1380 2” Front lower bump stops
RE1387 Rear bump stop pad
RE1476 JK front lower cam bolt set
RE1477 JK rear upper cam bolt set
RE1507 JK front brake line relocation brackets
RE1508 JK rear brake line relocation brackets
RE1607 Rear Lower Track Bar Bracket
RE1673 Front Adjustable Track Bar

TYPICAL TOOLS REQUIRED

Basic mechanics hand tools. Optional floor jack, jack stands, wheel chocks for ground installation.

INSTALLATION OVERVIEW

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

1. Installation of front coil springs , b u m p stops, track bar, front lower cam bolts, and brake line relocation brackets.

2. Installation of rear coil springs, bump stops, track bar bracket, brake line relocation brackets, sway bar links and rear upper cam
bolts.

3. Final detailing and adjustments.

RE7122-RE7142b Page 1 of 5

Step 1 – Front coil and component installation

A. With the vehicle and axle properly supported prepare the front end suspension component installation by removing the followi ng

items; shocks, sway bar links (from the axle end onl y), and track bar. Loosen but do not remove the lower control arm bolts at
the axle, they will be replaced later with caster adjusting cam bolts. The factory shocks and track bar will not be reinstalled on the
vehicle.

B. Remove the brake line attaching screw at the frame and let the lines hang loose until later in the install. DO NOT rem ove t he

brake lines or loosen the brake line fittings. Lower the breather hose clip on the shock tower approximately 3”.

C. Lower the axle and remove both coil springs.
D. Place the front bump stop on the center of the low er spring mount on the axle tube. Insert a center punch thru the center hole in

the bump stop and mark the hole to be drilled. Drill the marked hole to 5/16”

E. With the lower bump stop placed inside the new front coil spring, raise the small diam eter end of the coil into the upper spring

bucket and over the lower spring cup and bump stop pad. Rotate the coil spring so the end of the coil properly sits in the factory
pocket and install the supplied 3/8” self tapping bolt thru the bump stop and secure to the axle. (Photo #1)

F. Raise the axle towards the chassi s and install the new shock absorbers. (Purchased separately)

Photo # 1 Photo # 2

Front Track bar

A. Set the track bar at an initial setting of 32 7/8”. Loosely instal l the bushing end of the track bar into the axle mounti ng bracket

reusing the factory bolt and nut.

B. Using the factory bolt and supplied misalignment sleeves install the rod end into the factory track bar mount at the frame. Do not

fully tighten the track bar at this time, the axle center needs to be checked after completion of the entire syst em and the vehicle

is on the ground. The bend on the track bar will be with t he elb ow up to clear the front differential cover.
NOTE: It may be necessary to use a ratchet strap to pull the axle to the drivers sid e and install the track bar. Otherwise wait
until the vehicle is on the ground under its own weight to install the track bar at the fram e end . M oving the steering wheel back and
forth will assist in connection the track bar if the vehicle is on the ground.

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