Rubicon Express RE6300 - Manual (Page 2)

PRE INSTALLATION NOTE:
Control arm bushings are pre-lubed during initial assembly at Rubicon Express. As general maintenance the control arm bushings should be
lubed with a silicone base grease as needed. Silicone base grease can be purchased at your local auto parts store.
The Super-flex joints are also pre-lubed during initial assembly at Rubicon Express. As general maintenance the super-flex joints should be
greased as needed and the outer spanner nut tightened on the joint. Any type of grease will work on the Super-flex joints. Spanner nut
tools are available through Rubicon Express (RE3771 & RE3772) if needed for tightening of the joints.
LONG ARM INSTALLATION OVERVIEW (after steps 1-10 of RE6200 Instructions)
The installation of the long arm portion of the kit can be broken down into the following tasks:
1. Removal of factory lower control arm mounts from uniframe.
2. Front 3- piece crossmember.
3. Control arms.
Step 1 - Removal of factory lower control arm mounts on frame.
First, support vehicle by uni-frame (preferably on a lift) and work on a stable level surface. Support axle with jack
stands and perform steps 1-10 of the RE6200 system. Be sure to keep the front bolts from the lower arms as they
will be reused.
A. Cut off the factory lower control arm mounts from the uni-frame. Use extreme care as not to damage the
uniframe, or cut into existing brake, fuel, or electrical lines.
B. Grind rough areas smooth and repaint – refer to Photo 1 for typical bracket removal.
Photo 1 Photo 2
Step 2 - Front 3-piece crossmember
A. First, support transmission/transfer case and remove factory crossmember (and skid plate if there). Loosely bolt
transmission adapter plate to transmission mount so fitment can be checked with new crossmember in position.
The adapter should be positioned with the eight-hole surface up and off set to one side just like the factory
crossmember holes.
B. Note that the factory crossmember is held up by two bolts and two studs. The studs will have to be removed with a
stud removal tool or it may be possible to double nut them and back them out.
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C. Refer to Photo 2 for a layout of the right side components of the “3-Piece Crossmember”. Generally align the
center slots of the crossmember over the center slots of the left and right control arm mounts and loosely bolt them
together (through the four large counter sunk holes in the crossmember into the PEM nuts of the control arm
mounts) with the four supplied 1/2” flat head bolts. Loosely bolt assembly up into the four factory holes with the
supplied 10mm bolts and flat washers (early models use the front and middle holes and later models use the
middle and rear holes of the crossmember and control arm mounts) – refer to Photo 3. Align control arm mounts
so their pinch weld holes can be transferred through the horizontal pinch welds along the inside of the uni-frame
rails and tighten the four 10mm and four ½” flat head bolts. Check transmission adapter for hole alignment.