Rubicon Express RE6030 - Manual (Page 2)

RI 60106030 Page 2 of 4
INSTALLATION:
Note: 1984-1986 vehicles may require modifications to the front drive shaft for proper installation. These vehicles use a double offset joint, while later
vehicles use a double cardan (spicer) style CV joint. The spicer CV joint may be retro fitted to the earlier vehicles by changing the transfer case output
yoke for the later model. Lift heights this tall may require modifications to the rear driveshaft - see troubleshooting. Installation time should be approx.
8 hours.
1. Raise vehicle and support with stands.
2. Remove wheels.
3. Remove front shocks.
4. Remove front sway bar end links.
5. Disconnect front track bar at axle end.
6. Disconnect steering linkage at pitman arm.
7. Remove front spring retainers (at bottom) and springs.
8. Support the front axle with jack stands.
9. Remove brake hose mounting screw from inner fender well and straighten z shaped bend to lower brake hose. Re-attach brake hose to inner
fender well. If you purchased optional stainless lines, do not relocate the hard lines. Simply remove and replace your factory lines with the
supplied lines.
10. Remove the factory lower control arms. These will be replaced.
11. Install the lower control arms with the rubber bushing at the frame (use factory bolt at this end, and don’t fully tighten until vehicle is back on the
ground). The super-flex assembly bolts to axle bracket with supplied hardware. The offset tube is to be located as low as possible (see photo 1).
12. Install the front bump stop extensions by drilling a 5/16” hole in the center of the lower coil spring mount, then tightening the self-tapping bolt to
cut the threads. Next, remove the bump stop assembly and place it into the center of the coil spring.
13. Install the coil springs and retainers (do not over tighten the retainer bolt - it strips easily) with the bump stop extension in the center.
14. Tighten the bump stop extension bolt.
15. Install longer front shocks. Some require bar pins to be installed through the bottom shock eyes (use light grease).
16. Install sway bar quick disconnects per instructions supplied with disconnects (see photo 2).
17. Re-drill front track bar axle bracket over toward drivers side ¾”, center-to- center (or install optional adjustable front track bar). Reconnect track
bar at new hole.
18. Torque all bolts to factory specs. Double-check your work.
-REAR AXLE-
19. Remove the rear shocks.
20. Remove the rear sway bar (this will not be reused).
21. Support the rear axle.
22. Remove rear brake line and install supplied extended rear brake line.
23. Remove the U-bolts and rear leaf springs.
24. Add-a-leaf kit: Loosen any spring alignment clamps. Use c-clamps to clamp spring pack on each side of center pin. Remove center pin. Use vise
grip pliers on center-pin head. Carefully remove c-clamps. Insert add-a-leaf into spring pack. Add-a-leaf will go into spring pack in such a way as
to maintain the pyramid shape of the spring pack (see photo 3). Insert new center bolt through the spring pack with the head on the same side as
the old one (spring perch side). Use c-clamps to assist tightening of center bolt. Tighten to 20 ft/lbs. Replace the spring alignment clamps.
Leaf spring kit: Install new rear springs with new U-bolts in the same manner as factory springs – SEE PHOTO 3-B (don’t fully tighten spring
eyebolts until vehicle is back on the ground). The 3/8” center pins are stronger than stock and usually require enlarging the spring pad hole. The
pins usually come with spacers installed for use w/ floating type degree shims (see troubleshooting for typical shimming requirements). If required,
remove spacers so pin does not bottom out on axle tube. If using steel Rubicon Express shims, remove the spacers and replace with the shims
(SEE PHOTO 4). These steel shims will require reaming to 3/8” for 3/8” pins.
25. Reinstall springs and u-bolts. Do not fully tighten spring eyebolts until vehicle is back on the ground.
26. Install longer rear shocks. Some require bar pins to be installed through the top shock eyes (use light grease).
27. Install tires.
28. Thoroughly bleed brake lines and check for leaks.
29. Torque all bolts to factory specs (or specs supplied with parts) and double check your work.
30. Test drive and note location of steering wheel.
31. Adjust drag link to center steering wheel.
32. Align vehicle as soon as possible. We suggest Caster @ minimum setting and Toe @ Maximum setting per factory specs
33. Retighten all bolts after 50 miles and again after every off-road excursion.
34. Reminder: Do not reinstall the rear sway bar; it will not be reused.