Rubicon Express RE5505 - Manual

RUBICON EXPRESS 3290 MONIER CIR., RANCHO CORDOVA, CA. 95742 916-473-4600
INSTALLATION INSTRUCTIONS FOR:
RE5505 2.5” YJ STANDARD LEAF SPRING LIFT KIT
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.
KIT CONTENTS:
2 RXT2210 Rear Shocks
2 RXT2611 Front Shocks
1 RE1170 Sway bar disconnect kit
4 RE1430 Leaf springs
1 RE1492 4 Leaf springs main eye bushing kit
1 RE1465 Degree shims, 2.5” x 2* aluminum* (refer to
troubleshooting section)
1 RE1505 Front brake line extension
1 RE1513 Rear brake line
1 RE1630 Front track bar bracket
1 RE2100 Transfer case drop kit 1”
1 RE2420 Front u-bolt kit
1 RE2421 Rear u-bolt kit
REQUIRED TOOLS:
Basic mechanics' tools
Drill and ½’ bit
Floor jack
Jack stands (2 pair)
INSTALLATION:
Note: For optimum rear driveline performance we recommend a
slip yoke eliminator kit and CV drive shaft be used with this lift
(see slip yoke vibration in “troubleshooting” before proceeding).
1 Block rear wheels of vehicle.
2 Raise front of vehicle and support frame with jack stands.
3 Remove front wheels.
4 Remove front shocks.
5 Remove axle end of front track bar.
6 Support axle with jack stands.
7 Remove u-bolts & spring plates.
8 Remove springs.
9 Install front brake line extensions.
10 Lightly grease front main spring eye bushings. Main spring
eyes use the 9/16” id steel sleeves at double military wrap
end.
11 Install springs into vehicle with double military wrapped end
at the frame (see photo 1). The center pins may come with
spacers installed for use w/ floating type degree shims. Be
sure pins don’t bottom out on axle tube whether using shims
or not- remove spacers as required. Do not fully tighten
spring eye or shackle bolts at this time.
12 (See photo 2 for typical installation of steps 12-14) install
new u-bolts with old spring plates. Torque u-bolts to 65-80
ft/lbs, or u-bolt specs if supplied.
13 Install longer front shocks.
14 Install sway bar disconnects.
15 Torque spring eye and shackle bolts to factory specs.
16 Install front tires.
17 Lower front of vehicle.
18 Install axle end of front track bar with new bracket. Small
end of new bracket will fit into slot under factory mount (see
photo 3). Drill out old mounting hole to ½” and attach
bracket with supplied bolt. Attach track bar to bottom hole
with factory bolt.
-REAR AXLE-
19 Block front wheels of vehicle.
20 Raise rear of vehicle and support frame with jack stands.
21 Remove rear wheels.
22 Support rear axle with jack stands.
23 Remove shocks.
24 Remove rear track bar. This will not be reused.
25 Remove u-bolts & spring plates.
26 Remove rear springs.
27 Remove factory rear brake hose and replace with stainless
line.
28 Lightly grease and install main spring eye bushings. Main
spring eyes use the 9/16” id steel sleeves at double military
wrap end.
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