Rubicon Express RE7500 SERIES - Manual

RUBICON MANUFACTURING INC. 3290 MONIER CIR., RANCHO CORDOVA, CA. 95742 916-473-4600
INSTALLATION INSTRUCTIONS FOR:
RE7500 SERIES TJ EXTREME DUTY LONG ARM
TRI-LINK SYSTEM INCLUDING TJ UNLIMITED
Congratulations on purchasing the ultimate suspension upgrade available for the Jeep TJ.
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 (
without a drop pitman arm) can be used in the factory mounts for the 3.5” kits.
2) It is highly recommended that a slip-yoke eliminator and CV drive shaft be used in conjunction with this lift.
3) This kit requires modifications to the exhaust system. Generally, after the suspension 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 the 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, the installer will have to fabricate it.
5) Atlas transfer cases require a 1” body lift on the ’97-’02 kits and a modified or custom mount.
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 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.
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”
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”)
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
RE4045 (2) Extreme Duty Control Arm Rear Upper Tri-Link
RE4100 (’97-‘02) or RE4200 (’03-‘05) Extreme Duty Three Piece Belly Pan
RE4400 (’97-“02) or RE4405 (’03-“05) Tri-Link Rear Truss Kit
TYPICAL TOOLS REQUIRED
1” hole saw(s) for steel, ½” drill motor & drill bits (including a high quality 5/8” bit), angle grinder,
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)
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