Rubicon Express RE5515 - Manual (Page 2)

29 Lightly grease and install main spring eye bushings. Main
spring eyes use the 9/16” id steel sleeves at double military
wrap end.
30 Install new rear leaf springs into vehicle with double military
wrap end at the frame (ref. photo 1). The center pins may
come with spacers installed for use w/ floating type degree
shims. Be sure pins do not bottom out on axle tube whether
using shims or not- remove spacers as required. If using
steel Rubicon MFG’s shims, remove the spacers and replace
with the shims. These steel shims will require reaming to
3/8” for 3/8” pins.
31 If using, insert 4* wide shim between spring and spring pad
on axle. Thicker end of shim should be at front of vehicle
(pinion points up).
32 Slightly snug bolts. DO NOT fully tighten the spring eye or
shackle bolts at this time. Bolts will be tightened to spec
once the vehicle is on the ground (step 41).
33 Install new u-bolts with old spring plates. Torque u-bolts to
65-80 ft/lbs, or u-bolt specs if supplied.
34 Install longer rear shocks.
35 If using, install transfer case drop kit by supporting one side
of transfer case with floor jack. Remove hardware from one
side of cross member. Install spacers and new hardware.
Tighten to 55 ft/lbs. Repeat on opposite side.
36 Lower axle so it is at full droop. Rotate the rear drive shaft
to insure the yokes do not bind. If yokes bind and shims are
installed properly, a slip yoke eliminator and CV drive shaft
are likely required.
37 Lower rear of vehicle to ground.
38 Bleed brake system. Inspect all brake hoses and lines for
leaks, kinks or damage.
39 Grease all zerk fittings on new bushings.
40 Lengthen drag link to center steering wheel.
41 Recheck all bolts - use factory torque specs if not given.
Recheck after 50 miles and then after every off road
excursion.
42 Reminder: Do not reinstall the rear track bar; it will not be
reused.
< FRAME END (MILITARY WRAP) – PHOTO 1 – SHACKLE END >
PHOTO 2
PHOTO 3
LIFT KIT TROUBLESHOOTING
REAR DRIVELINE:
Acceleration vibration: Caused by the pinion being too high in relation
to the transfer case output shaft. On leaf sprung vehicles, install axle
shims to lower pinion accordingly.
Deceleration vibration: Caused by the pinion being too low in relation
to the transfer case output shaft. On leaf sprung vehicles, install axle
shims to raise pinion accordingly.
Slip yoke vibration: Caused by excessive angle at the rear transfer case
slip yoke. Very common on vehicles with 2” or more of lift. The transfer
case drop kit and shims provided may be an acceptable temporary fix
(pinion adjustment may also be required- see acceleration and
deceleration vibration troubleshooting above). If this is not acceptable,
a slip yoke eliminator and CV drive shaft is likely required and highly
recommended. Adjust pinion so it is 2 degrees below parallel with CV
drive shaft (see acceleration and deceleration vibration troubleshooting
above). Note that transfer case drop kits can usually be omitted when
using a CV drive shaft.
RI5515 Page 2 of 3