Rubicon Express RE5515 - Manual

RUBICON EXPRESS. 3290 MONIER CIR., RANCHO CORDOVA, CA. 95742 916-473-4600
INSTALLATION INSTRUCTIONS FOR:
RE5515 4.0” 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 RXT2410 Rear shocks
2 RXT2811 Front shocks
1 RE1180 Sway bar disconnect kit
4 RE1425 Leaf springs
1 RE1492 4 Leaf springs main eye bushing kit
1 RE1466 Degree shims, 2.5” x 4* aluminum
1 RE1505 Front brake line extension
1 RE1513 Rear brake line
1 RE1630 Front track bar bracket
1 RE2007 YJ rear shock relocator
1 RE2100 Transfer case drop kit 1”
1 RE2420 Front u-bolt kit
1 RE2421 Rear u-bolt kit
1 RE2500 Pitman Arm P/S
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 leaf springs.
9 Install new 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 leaf 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 do not bottom out on axle tube whether using
shims or not- remove spacers if needed. Slightly snug bolts.
DO NOT fully tighten the spring eye or shackle bolts at this
time. Bolts will be tightened to spec once the vehicle is on
the ground (step 18).
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 Use tie rod removal tool to remove drag link at pitman arm.
Use a puller to remove stock pitman arm. Install new drop
pitman arm and stock drag link
14 Install longer front shocks.
15 Install sway bar disconnects.
16 Install front tires.
17 Lower front of vehicle.
18 Torque spring eye and shackle bolts to factory specs.
19 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 top hole with
factory bolt.
-REAR AXLE-
20 Block front wheels of vehicle.
21 Raise rear of vehicle and support frame with jack stands.
22 Remove rear wheels.
23 Support rear axle with jack stands.
24 Remove shocks.
25 Remove rear track bar. This will not be reused.
26 Remove u-bolts & spring plates.
27 Remove stock rear leaf springs.
28 Remove factory rear brake hose and replace with new
stainless line.
RI5515 Page 1 of 3