Rubicon Express RE7200 User Manual

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

INSTALLATION INSTRUCTIONS FOR:

RE7200 SERIES TJ EXTREME DUTY LONG ARM SYSTEM

INCLUDING LJ UNLIMITED

Application Notes:

1) The TJ long arm system was originally designed for 5.5” lift. The front track bar may be marginally long for the 4.5” lift and is too
long for the 3.5” lift. The male thread of the RE1610 bar can be shortened by about 3/8” to allow shortening the bar to better
center the axle. An RE1600 front track bar (
rear track bar may be a bit long for the 4.5” kit and is long for the 3.5” lifts as well. Adjust the bar a s short as possible for the

4.5” and omit the bracket on the 3.5”.

2) It is highly recommended that a slip-yok e eliminator and CV drive shaft be used in conjunction with this lift.

3) This kit requires modifications to t he exhaust system. Generally, after the suspensio n is installed, plan on a shop installing a
system from the rear of the cat on back with a smaller muffler.

4) The “Rubicon” model TJ’s will require that t he installer fabricate a bracket to relocate the compressor (refer to Photo 2 for an
example). Also, “Rubicon” model TJ’s with automatics will have to remove the transmission skid plate for drive shaft clearance. If
more transmission protection is required, th e installer will have to fabricate it.

5)

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:
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.

Atlas transfer cases require a 1” body lift on the ’97-’02 kits and a modified or custom mount.

KIT CONTENTS

Front Coil Springs 3.5” Kit: RE1363, 4.5” Kit: RE1355, 5.5” Kit: RE1352
Rear Coil Springs 3.5” Kit: RE1365, 4.5” Kit: RE1360, 5.5” Kit: RE1353

RE1155 Sway Bar End Links
RE1142 Gen2 Sway Bar Disconnects
RE1383 Bump Stops Front3” (5.5” only), RE1380 2” (3.5” & 4.5”)
RE1385 Bump Stop spacers Rear 1.5”
RE1395 Bump Stops Rear 1.5” Extended (5.5”only)
RE1517 Brake Line SS Rear 24”
RE1550 Brake Line SS Front 22”
RE1602 Rear Track Bar Bracket
RE1610 Front Extreme Duty Track Bar (recommend RE1600 for 3.5” and 4.5”)
RE1611 Front Extreme Duty Drop Track Bar Bracket (recommend omitting for 3.5” and 4.5”)
RE1620 Rear Adjustable Track Bar
RE2035 Rear Shock Relocation Mount
RE2500 Drop Pitman Arm
RE4000 Extreme Duty Control Arm Front Lower Left
RE4010 Extreme Duty Control Arm Front Lower Right
RE4020 (2) Extreme Duty Control Arm Front Upper
RE4030 (2) Extreme Duty Control Arm Rear Lower
RE4040 (2) Extreme Duty Control Arm Rear Upper
RE4100 (’97-‘02) or RE4200 (’03-‘05) Extreme Duty Three Piece Belly Pan

Congratulations on purchasing the ultimate suspension upgrade available for the Jeep TJ.

wi hout

a drop pitman arm) can be used in the factory mounts for the 3.5” kits. The

t

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TYPICAL TOOLS REQUIRED

1” hole saw(s) for steel, ½” drill motor & dril l bits (including a high quality 5/8” bit), angle grind e r,
Basic mechanical hand tools and T-55 Torx head bit along with standard Torx head wrench set,
Floor jack & jack stands (2 Pair), Pitman arm puller, welder
Plasma cutter, or reciprocating saw w/metal cutting blades, or cutting wheels for angle or die grinder (to remove control arm mounts)

INSTALLATION OVERVIEW

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

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

2. 3-piece frame crossmember.

3. Control arms.

4. Bump stops and coils.

5. Track bars, pitman arm and sway bar links.

6. Brake lines and shocks.

7. Final detailing and adjustments.

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

A. First, support vehicle by frame (preferably on a lift) and work on a stable level surface. Support axles with jack stands and

remove the following components; shock s, track bars, sway bar end links, coil springs, control arms, bump stops, brake hoses
from axle end (it may be helpful to pinch-off hoses with vise grips to minimize fluid loss until new SS hoses are installed in step

6), and exhaust system behind the catalyt ic converter. NOTE: Coil springs can be removed without compressors if enough
distance is generated between the axle and frame). If a lift is not being used, it may be easier to do this one side at a time on
one axle at a time. CAUTION: If using coil spring compressors use extreme care as they will be holding a lot of potential energy
and can release violently.

B. Cut off the (4) factory low e r control arm mounts from the frame. Use extreme care as not to damage the frame, or cut into

existing brake, fuel, or electrical lines.

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

Photo 1 Photo 2

Step 2 - 3-piece frame crossmember

A. Support transmission and transfer case and remove stock crossmemb er. N ote that the “Rubicon” model TJ’s will require that the

installer fabricate a bracket to relocate the compressor (refer to Photo 2 for an example).

B. Assemble the right and left control arm mounts to the center section using only a few supplied flat head bolts for fitm ent

purposes – refer to Photo 3 for orientation of parts. We will refer to this assembly from here on out as the “crossmem ber”.

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C. Install crossmembe r using t h e six factory mounting bolts. Keep in mind that the two Pem nuts sticking up from each control arm

mount will prevent the crossmember from fitting up flat against the frame bottom until the recess holes in step ‘F’ are ma de.
Verify fitment to frame, transmission, transfer case and exhaust. This is the easiest time to make changes and ins tall and remove
the pan. Make note to adjust transfer case linkage and verify clearances.

D. Be sure to pull fuel lines, brake lines, etc. clear of drilling. With crossmember in place, mark with a center punch (through the

Pem nuts) the location of the 2 recess holes required in the b ot tom of each frame rail. You will need to drill a 3/16” pilot hole at
these four center punch marks.

E. Rem ove pan and drill out the four pilot holes on ce nter with a 1” hole saw – refer to Photo 4. Paint all bare metal for protection.

Photo 3

F. Attach right and left frame brace to crossmember, only finger tight, using two ½” bolts on each side into the Pem nuts – refer to

Photo 5 for front view of right side assembly ( les s center section). Note large notch in brace is toward rear for clearance around
body mount. Reinstall entire crossmember/frame brace assembly to frame.

Photo 5

G. With crossmember centered and frame braces tight against frame rails you are now ready to transfer mark the 3 holes on the

side of both frame braces. Use a center punch or other method to accurately mark hole location to frame rail. After marking
remove crossmember/frame brace assembly from frame once again.

Photo 4

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