Rubicon-express RE8005 User Manual download pdf

RUBICON EXPRESS. 3290 MONIER CIR., RANCHO CORDOVA, CA. 95742 916-473-4600

INSTALLATION INSTRUCTIONS FOR:

RE8005 3.5” ZJ SUPER-RIDE SUSPENSION SYSTEM

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.

KIT CONTENTS:

RE1150 Rear sway bar end links

RE1171 Sway bar end link adapters (93-95)

OR RE1172 (96-98)

RE1175 Front sway bar end links

RE1341 Front coil springs

RE1343 Rear coil springs

RE1604 Rear track bar bracket

RE3705 Lower front control arms

RE3720 Lower rear control arms

REQUIRED TOOLS:

Basic mechanics' hand tools

Jack stands and floor jack

Spring compressors

Drill motor and drill bits

PRE INSTALLATION NOTE:

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.

RI8005 Page 1 of 2

INSTALLATION:

uire a transfer case drop kit or

tands.

r end links.

ps.

Disconnecting steering at

¾”,

r end links.

arms that are to be replaced.

rear

shim to take up space between

bracket and axle mount at top 5/16” bolt.

ote: Lift heights of 3.5” may reqN

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

troubleshooting before proceeding.

1. Raise vehicle and support with s

2. Remove wheels.

3. Remove front shocks.

4. Remove front sway ba

5. Remove front spring retainer clam

6. Disconnect front track bar at axle end.

pitman arm makes axle droop out farther.

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

Support the front axle with jack stands. 8.

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

10. Use factory eccentric hardware at front axle lower control ar

mount.

11. Install the lower control arms with offset tube being mounted a

low as possible (see photo 1). Use the factory bolt and nut at the

uni-body mount (don’t fully tighten bolts until vehicle is back on th

ground).

12. The front springs are the longer ones. Coil spring compressors may

be useful. Rotate the coil to index the spring with lower coil cup.

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

Install longer front shocks. Bar pins may need to be put through th14.

bottom shock eyes (use light grease).

15. Install sway bar end link adapters per instructions supplied with

adapters. Install sway bar end links (see photo 2 for typical

installation).

16. Re-drill front track bar axle bracket over toward driver's side

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

Reconnect track bar at new hole.

-REAR AXLE-

1 Remove the rear shocks.

Remove the rea18. r sway ba

19. Support the rear axle.

20. Disconnect rear track bar at axle.

21. Remove the factory lower control

22. Remove the rear springs.

23. Remove the plastic dust shield that covers the bolt securing the

track bar to the mount on the axle housing and discard.

24. Remove the Torx head bolt (t55) and disconnect axle end of track

bar, if not done previously

25. Install track bar bracket using the supplied ½” bolt and spacer (the

spacer goes in the location vacated by the track bar to prevent the

bracket from deforming when the bolt is tightened- see photo 3 for

similar installation).

26. With the track bar bracket in place, drill two 5/16” holes in the axle

mount where the plastic dust shield was previously located, one on

top and one on angled surface.

27. Install the 5/16” hardware in the holes drilled in step #27. If

required, use supplied horseshoe

1 2

TROUBLES 2

Summary of Contents

Page 1

RUBICON EXPRESS. 3290 MONIER CIR., RANCHO CORDOVA, CA. 95742 916-473-4600 INSTALLATION INSTRUCTIONS FOR: RE8005 3.5” ZJ SUPER-RIDE SUSPENSION SYS

Page 2 - TROUBLES

RI8005 Page 2 of 2 lt r s low as possible (see photo 4). Use the factory y torque specs. of steering wheel. Adjust drag link to heel. minimum 0 m

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Rubicon-express RE8005 User Manual

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