Rubicon Express RE8003 - Manual (Page 2)

23. Disconnect rear track bar at axle.
24. Remove the factory lower control arms that are to be replaced.
25. Remove the rear springs.
26. Remove the plastic dust shield that covers the bolt securing the rear
track bar to the mount on the axle housing and discard.
27. Remove the Torx head bolt (t55) and disconnect axle end of track
bar, if not done previously.
28. 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).
29. 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.
30. Install the 5/16” hardware in the holes drilled in step #29. If
required, use supplied horseshoe shim to take up space between
bracket and axle mount at top 5/16” bolt.
31. Install the track bar in the track bar bracket using the Torx bolt
removed in step #27. It may be easier to do this later with weight
on the vehicle.
32. Set rear lower control arm length to 17.25” for 3.5” lift. Install the
lower control arms with the rubber bushing at the uni-body and
super flex end at the axle. The offset tube should be mounted as
low as possible (zerk on top - see photo 4). Use the factory
hardware at the uni-body and supplied bolt at the axle mount (don’t
fully tighten until vehicle is back on the ground).
33. Remove the rubber insert from the rear bump stop. Remove the
bump stop cup. Place the spacer between the bump stop cup and
the frame member of the uni-body using the supplied longer metric
hardware (see photo 5). Reinstall rubber bump stop.
34. Install springs. Spring compressors may be helpful.
35. Install replacement sway bar end links.
36. Install longer rear shocks.
37. Install all tires.
38. Thoroughly bleed brake lines and check for leaks.
39. Double-check all nuts and bolts to factory torque specs.
40. Test drive and note location of steering wheel. Adjust drag link to
center steering wheel.
41. Align vehicle as soon as practical. A good rule of thumb is minimum
factory caster and maximum factory toe-in.
42. 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
< UNI-BODY END – PHOTO 4 – AXLE END (ZERK ON TOP) >
RI8003 Page 2 of 3