Rubicon Express RE7500 SERIES - Manual (Page 3)

D. Install crossmember using the six factory mounting bolts. Keep in mind that the two Pem nuts sticking up from each control arm
mount will prevent the crossmember from fitting up flat against the frame bottom until the recess holes in step ‘F’ are made.
Verify fitment to frame, transmission, transfer case and exhaust. This is the easiest time to make changes and install and remove
the pan. Make note to adjust transfer case linkage and verify clearances.
E. Be sure to pull fuel lines, brake lines, etc. clear of drilling. With crossmember in place, mark with a center punch (through the
Pem nuts) the location of the 2 recess holes required in the bottom of each frame rail. You will need to drill a 3/16” pilot hole at
these four center punch marks.
F. Remove pan and drill out the four pilot holes on center with a 1” hole saw – refer to Photo 4. Paint all bare metal for protection.
Photo 4
G. Attach right and left frame brace to crossmember, only finger tight, using two ½” bolts on each side into the Pem nuts – refer to
Photo 5 for front view of right side assembly (less center section). Note large notch in brace is toward rear for clearance around
body mount. Reinstall entire crossmember/frame brace assembly to frame.
Photo 5
H. With crossmember centered and frame braces tight against frame rails you are now ready to transfer mark the 3 holes on the
side of both frame braces. Use a center punch or other method to accurately mark hole location to frame rail. After marking
remove crossmember/frame brace assembly from frame once again.
I.
Use a 3/16” drill bit to run a pilot hole through both sides of frame at all six hole locations. Use care to drill perpendicular to
frame.
J.
Use 1” hole saw to enlarge the six pilot holes only on outside surface of frame rail, and use ½” drill bit to enlarge the six pilot
holes only on inside surface of frame rail opposite of 1” hole –
refer to Photo 6.
RE7500A Page 3 of 8