Rubicon Express RE6200 - Manual (Page 2)

install a lower profile bump stop. You can also cut bend and re-weld
the tower for extra clearance.
17. Install the spring retainer removed in step 6. Use caution, this bolt
strips easily.
18. Install longer front shocks. Some require bar pins to be installed
through the bottom shock eyes (use light grease).
19. Install adjustable front track bar and bracket per instructions
supplied. Do not attach adjustable side until weight is on vehicle
and axle is centered.
20. Install sway bar quick disconnects per instructions supplied with
disconnects (SEE PHOTO 2).
21. Install new front brake lines using supplied anchor brackets.
22. Torque all bolts to factory specs and double check your work.
-REAR AXLE-
23. Remove the rear shocks.
24. Remove the rear sway bar. This will not be reused.
25. Support the rear axle.
26. Remove rear brake line and install supplied extended rear brake
line. Use line wrenches to avoid rounding off fittings. Tighten brake
line fittings before bleeding brakes.
27. Remove the u-bolts.
28. Remove factory spring packs.
29. Install new extended rear shackles (SEE PHOTO 3)
30. Install new springs in same manner as factory leaves (SEE PHOTO
4). (Don’t fully tighten spring eyebolts until vehicle is back on the
ground). The 3/8” center pins are stronger than stock and will
require enlarging the spring pad hole. The pins come with spacers
installed for use w/ floating type degree shims. Be sure spacers
don’t bottom out on axle tube – remove spacers as required. If
using steel Rubicon shims, remove the spacers and replace with the
shims (SEE PHOTO 5). These steel shims will require reaming to
3/8” for 3/8” pins.
31. Install new u-bolts.
32. Install longer rear shocks. Some require bar pins to be installed
through the top shock eyes (use light grease).
33. Install tires.
34. Lower vehicle to ground and adjust front track bar to center front
axle per instructions supplied with track bar.
35. Thoroughly bleed brake lines and check for leaks.
36. If installing RE2120 transfer case drop kit (see troubleshooting)
install it now. Support cross member with floor jack. The cross
member is factory mounted with two studs and two bolts. The studs
will have to be removed with a stud remover or by double nutting
them and backing them out. Lower the cross member just enough
to insert the spacers at each bolt hole and install bolts and washers.
37. Double-check all nuts and bolts.
38. Test drive and note location of steering wheel.
39. Adjust drag link to center steering wheel.
40. When possible, align vehicle to minimum factory caster and
maximum factory toe-in specifications.
41. Reminder: Do not reinstall the rear sway bar; it will not be reused.
< FRAME END (RUBBER) - PHOTO 1 - AXLE END (ZERK ON TOP) >
PHOTO 2
< TOWARD FRONT – PHOTO 3 – TOWARD REAR >
< FRAME END (LARGE BUSHING) – PHOTO 4 – SHACKLE END >
PHOTO 5
RI6200 Page 2 of 3