Rubicon Express RE8003 User Manual

Kit contents, Required tools, Installation

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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.



Rear sway bar end links


Gen2 sway bar disconnects


Front coil springs


Rear coil springs


Front bump stop extensions


Rear bump stop extension


Front brake lines ss.


Rear track bar bracket


Lower front control arms


Lower rear control arms


Basic mechanics' hand tools

Jack stands and floor jack

Spring compressors

Drill motor and drill bits


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. A spanner nut

tool is available through Rubicon Express (RE3772) if needed for

tightening of the joints.


Note: Lift heights of 3.5” may require a transfer case drop kit or

modifications to the rear drive shaft – see slip yoke vibration in

troubleshooting before proceeding.

1. Raise vehicle and support with stands.

2. Remove wheels.

3. Remove front shocks.

4. Remove front sway bar end links.

5. Remove front spring retainer clamps.

6. Disconnect front track bar at axle end. Disconnecting steering at

pitman arm makes axle droop out farther.

7. Remove front springs. Spring compressors may be helpful.

8. Support the front axle with jack stands.

9. Remove factory lower control arms that are to be replaced.

10. Remove factory brake lines and replace with supplied lines. Some

require positioning the block and line vertically at the caliper. Watch

line routing, use angle brackets and e-clips.

11. Drill 5/16” hole in center of lower spring pads.

12. Use self-tapping bolt through bump stop extension spacer to cut

threads in lower spring pad. Remove bolt and spacer, it will be

installed with the spring.

13. If so equipped, use factory eccentric hardware at front axle lower

control arm mount. If not, use the supplied bolt.

14. Install the lower control arms with the rubber bushing at the uni-

body. Use the factory bolt and nut at the uni-body mount (don’t

fully tighten until vehicle is back on the ground). The super-flex

joint will be installed at axle with offset tube being mounted as low

as possible (zerk on top - see photo 1).

15. The front springs are the longer ones. Install the front springs with

the 2” bump stop extension inside of the coil. Coil spring

compressors may be useful. Once the spring is in place, thread the

bolt into the lower spring pad (ref. step #12). Rotate the coil to

index the spring with lower coil cup.

16. Install the spring retainer clamp removed in step #5.

17. Install longer front shocks. Bar pins may need to be put through the

bottom shock eyes (use light grease).

18. Install sway bar quick disconnects per instructions supplied with

disconnects (see photo 2 for typical installation).

19. Re-drill front track bar axle bracket over toward driver's side ¾”,

center-to-center (or install optional adjustable front track bar).

Reconnect track bar at new hole.


20. Remove the rear shocks.

21. Remove the rear sway bar end links.

22. Support the rear axle.

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