Rubicon Express RE7330 Manuale utente

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

INSTALLATION INSTRUCTIONS FOR:

RE7330 2 & 4 DOOR JK WRANGLER

LONG ARM UPGRADE KIT

Congratulations on purchasing the ultimate suspension package available for the Jeep JK.

Application Notes:

1) The JK long arm upgrade kit is not a complete kit, additional parts such as but not limited to coil springs, track bars, track bar

brackets, and steering components will also be needed for a complete installation. This kit is designed to replace the stock short

arm configuration. Installation of the system will require the rear lower rear control arm brackets are removed from the frame

along with modification or removal of the upper rear arm brackets. The front lower control arm brackets can remain on the frame

but we suggest that they are removed for a better visual appearance.

2) This kit does require the removal of the fuel tank for installation. Special tools are not required to remove the fuel tank.

3) This kit does not require modifications to the exhaust system, however it is recommended that the exhaust, from the transmission

cross member back is removed prior to and replaced after installation to better access the frame rail during rear bracket

installation.

4) The transmission skid plate must be removed and will not be reinstalled due to drive shaft clearance.

5) It is absolutely necessary that a front and rear CV drive shaft be used in conjunction with this lift.

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 seat belt, 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:

All procedures described in these instructions were performed while the vehicle was properly supported on a vehicle lift. Use caution when

supporting the vehicle as removing and installing parts will change the vehicle center weight. Rubicon Express recommends that chassis support

jacks are always used at the front and rear of the vehicle during the installation of a suspension system.

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.

ESP WARNING NOTE: The 2007+ Jeep Wrangler JK is equipped an Electric Stability Program (ESP). This system is designed to help control

the vehicle in times of uncertain traction conditions and roll stability. Due to the complex nature of this program Rubicon Express strongly

suggest that after lifting the vehicle it is returned to the dealer for a computer “flash” to re address tire size and proper ESP control settings.

Rubicon Express also recommends that you become familiar with the ESP controls and how the different level of settings can help you to keep

better control of your vehicle.

KIT CONTENTS

RE4070 Extreme Duty Control Arm Front Lower Left

RE4080 Extreme Duty Control Arm Front Lower Right

RE4075 Extreme Duty Control Arm Front Upper, pair

RE4085 Extreme Duty Control Arm Rear Lower Left

RE4095 Extreme Duty Control Arm Rear Lower Right

RE4090 Extreme Duty Control Arm Rear Upper, pair

RE4520 3 Piece Extreme Duty Front Cross Member

RE4525 Rear Control Arm Bracket kit

TYPICAL TOOLS REQUIRED

1. Basic mechanical hand tools

2. 1” & 1.25” bi-metal hole saws

3. ½” drill motor & drill bits

4. angle grinder

5. welder

6. plasma cutter, or reciprocating saw w/metal cutting blades, or cutting wheels for angle or die grinder (to

remove control arm mounts) RI7330 Page 1 of 9

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.

The Super-flex joints are also pre-lubed during initial assembly at Rubicon Express. As general maintenance the super-flex joints should be

greased as needed and the outer spanner nut tightened on the joint. Any type of grease will work on the Super-flex joints. Spanner nut

tools are available through Rubicon Express (RE3771 & RE3772) if needed for tightening of the joints.

INSTALLATION OVERVIEW

The installation process can be broken down into the following tasks:

1. Vehicle preparation for suspension installation

2. Installation of 3 piece front cross member assembly

3. Installation of front control arms

4. Installation of rear control arm brackets

5. Installation of rear control arms

6. Final detailing and adjustments

Step 1 – Vehicle preparation

Prepare the vehicle for the suspension installation by removing the following parts from the vehicle. The transfer case

skid plate (4 Door models), fuel tank and exhaust will be re-installed at the end of the installation.

1. Automatic transmission skid plate (if equipped)

2. Transfer case skid plate

3. Front and rear drive shafts

4. Fuel tank.

5. Exhaust, from the collector at the cross member to the muffler

FUEL TANK REMOVALL: Special tools are not required for the removal of the fuel tank. All plastic clips should come apart by

squeezing the outer portion of the clip and gently pulling apart. The following connections need to be

removed: supply and return at the front of the tank, large plastic line at the charcoal canister, vent hose at

fuel tank, and the fuel filler hose. DO NOT use excessive force, damage to the fittings or seals may result.

The fuel tank removal should be done when there is less than 1/8 tank of fuel in the tank to avoid excess fuel

sloshing weight. Before lowering the tank back out the bolt from the right rear lower control arm to avoid

dragging the side of the tank on the end of the bolt. Do not completely remove the bolt at this time.

Caution: With the fuel tank removed, there may be fuel vapors present. Use good judgment when drilling,

cutting, and welding near the fuel system components.

Step 2 – Three Piece cross member installation.

A. Prepare the new cross member, RE4520, by loosely installing the supplied ½” bolts thru all 3 pieces before trying to install into

the vehicle. The shorter of the two ½” bolts install from the front to the back and the longer of the two from the back to the

front. Install the 4, 3/8” flat head bolts into the bottom of the cross member and tighten, then tighten the prior installed ½” bolts

to Installing the hardware in this fashion will allow the removal of the center cross member section without removal of the front

lower control arms should transmission service become necessary. (photo 1)

B. Support the transmission/transfer case assembly at the rear output shaft. Remove the 3 transmission mount nuts and 4 cross

member nuts.

C. Gently lift the transmission/transfer case assembly to relive the weight off the factory cross member. Remove the 4 cross member

thru bolts and remove the factory cross member. (photo 2)

D. Install the new Rubicon Express cross member into the factory mounts with the control arm pockets facing forward. Insert the

nut strip in the square hole and start the forward mounting ½” bolt. Rotate the brace to the front side of the cross member

mounts and reinstall the 4 factory cross member bolts thru the brace and cross member. Tighten to 55 ft/lbs. (Photo 3)

E. Insert the frame rail nut strip thru the hole in the frame rail and bolt thru the cross member brace and frame rail.

F. Lower the transmission, install and tighten transmission mount nuts. Re check and tighten all hardware.

Photo # 1

RI7330 Page 2 of 9

Photo #2 Photo#3

Step 3 – Front arm installation

Front arm Installation

A. Prepare the new Rubicon Express front lower long arms by pre setting the length to 36 ½”

NOTE: All measurements given are for starting points, depending on the lift height and wheelbase desired your measurements

may differ from our recommended starting point.

B. Remove the passengers side factory upper and lower control arms.

NOTE: It will be necessary to cut the upper control arm bolt off at the frame end to remove the passenger upper front arm.

This is due to the bolt being installed from the inside out prior to the exhaust installation from the factory. Alternatively

the head pipe assembly can be removed to pull the bolt out of the frame bracket. If choosing to unbolt the head pipe

be sure to disconnect all O2 sensors before removal. (photo 4)

C. Using the supplied 9/16” x 4.5” bolt from the Rubicon Express front arm kit, install passengers side arm (pocket bracket faces

drivers side) into the cross member mount. (photo 5) Next install the bushing end of the arm into the stock control arm location

on the axle housing using the stock hardware.

D. Set the upper arms to 15 1/8”. With the supplied ½” bolt install the rubber bushing end into the pocket on the lower control arm

and the fork of the arm over the bushing mount on the axle. Use the factory hardware thru the fork end of the arm. (photo 6)

NOTE: The rubber coupler is welded at an offset angle. Be sure when installing the arm that the bushing is in a neutral

position. If the arm does not drop over the upper mount remove the ½” bolt and rotate the coupler 180 degrees.

E. Repeat steps A – D on the drivers side

F. Tighten the lower control arm bolts at the cross member only, all other rubber attaching points should remain loose until the

vehicle is under its own weight to prevent bushing preload.

Photo # 4 Photo # 5

RI7330 Page 3 of 9

Photo # 6 Photo # 7

Front bump stops and coil springs

A. Place the front bump stop on the center of the lower spring mount on the axle tube. Insert a center punch thru the center and

mark the hole to be drilled. Drill the marked hole to 5/16”, use the supplied self-tapping bolt to secure the bump stop to the

lower spring cup.

B. Raise the small diameter end of the coil into the upper spring bucket and over the lower spring cup and bump stop. Then raise

the axle to seat the upper mount and rotate the coil to properly index in the lower mounts.

NOTE: If the axle cannot be dropped far enough from the frame due to brake line or ABS wire length to install the coil springs

remove the bump stop and insert it into the coil. Then slide the coil over the stock axle mount and re-install the bump stop bolts.

(photo 7)

Front track bar bracket

A. Remove the forward two factory steering box bolts, place the new drop bracket into the stock track bar bracket and reinstall the

two factory steering box bolts. (photo 8)

B. With the steering box bolts tight, mark the ½” hole on the coil spring tower. Remove the steering box bolts and bracket and drill

the marked hole to ½”. (Photo 9)

C. Reinstall the track bar bracket with the steering box bolts. Use the supplied ½” hardware to bolt thru the coil spring tower and

track bar bracket and the 9/16” bolt with sleeve thru the stock track bar location. Torque the steering box bolts then the 9/16”

bolt, both to 60 ft/lbs. Torque the ½” bolt to 50ft/lbs. (photo 10)

Photo#8 Photo#9

RI7330 Page 4 of 9

Photo # 10 Photo # 11

Front Track bar

A. Set the track bar at an initial setting of 32 5/8” center to center.

B. Using the supplied ½” bolt, install the Super-Flex end of the bar into the drop track bar bracket. Using the stock track bar bolt,

install the bushing end into the axle bracket. Do not tighten the axle end until the final length check at the end of the installation

and the vehicle is sitting on its own weight. (Photo 11)

Front brake lines, shocks, and sway bar links/disconnects

A. Remove and replace the front brake lines with the included stainless steel brake lines. The lines are left and right specific, when

installed the 90 degree leader from the caliper should be leaning away from the tire. (photo 12)

B. Depending on what shocks have been purchased with the suspension system, it may be necessary to reuse the sleeves and bar

pins from the stock shocks. If this is necessary be sure to lubricate the sleeves or bar pins during removal and most importantly

during re-installation.

C. See supplied instruction sheet for the front sway bar link / disconnect information (RE1143). This kit contains all parts necessary

to be used on a Jeep Rubicon model with factory electronic disconnect as well as X and Sahara Jeep models.

Photo#12 Photo#13

Step 4 – Rear control arm bracket installation

NOTE: 1. The rear control arm brackets can and should be installed before any of the stock rear suspension

components come off of the vehicle. This will keep the axle in place while working around the rear section of

the frame. In addition, the lower rear control arm brackets must be removed and the uppers removed or at

least relief cut.

2. Two Door models will require that the forward exhaust hanger and t-case skid mount nut be cut off

of the frame and sanded smooth for proper bracket clearance.

3. If the vehicle is equipped with factory rocker skids it may be helpful to remove the rockers before

going forward with the control arm bracket installation.

CAUTION: During the next few steps we recommend constantly double checking the marked hole locations, pilot drill

locations and final drill locations. Doing so will result in a better fit without the need to ream holes for proper installati

RI7330 Page 5 of 9

A. First, separate the six brackets (3 per side) that make up the left and right bracket kits. The brackets in the photo are shown

as left and right assemblies with the top of the photo being the front of the vehicle. (Photo 13)

B. Using the drivers side inner reinforcement plate, locate the indexing oval on the inside of the driver frame rail. Mark the 2

countersunk holes at the rear of the bracket and 3 square holes. (photo 14)

C. Using the same drivers side inner reinforcement plate, repeat step B on the passenger outside frame rail with the addition of

marking the 3/16” hole near the bottom center of the plate. (photo 15)

D. Using the passenger side inner reinforcement plate repeat steps B & C on the inside passenger and outside driver frame

rails.

E. Using a 1.25” hole saw, cut the relief hole for the outer nut plate to sit flush against the outside frame rail. (photo 16)

F. Locate the outer nut plate over the outside frame rail and double check the prior marked three square and two tapered

holes. If the alignment is good drill the remainder of the marked holes to 3/16”

G. On the inside of the frame us a 1” hole saw to open the two rear most vertically marked and pilot drilled holes for the ½”

I.D. threaded weld spacers. Drill all other holes to ½” thru both frame rails.

H. Place the outer nut plate on the outside frame rail. Using a spare ½” bolt, partially engage the threaded spacers on the bolt

and insert thru the inside of the frame. Insert the ½” tapered head bolt thru the nut plate and into the spacer from the

outside frame rail, tighten to secure and remove the spare bolt from the spacer. Weld each spacer to the inside of the frame

rail, sand the frame smooth if necessary and paint all raw steel. (Photo 17)

NOTE: When welding the spacers to the inside frame rail it may be helpful to leave the spare bolt in the spacer to prevent the

weld berries from entering and damaging the threaded spacer.

I. Place the inner reinforcement plate on the inside frame rail and insert the three ½” carriage bolts thru all three brackets.

Install the two ½” tapered head bolts from the inside to the threaded spacers and tighten. (photo 18)

J. Using washers and nylock nuts, tighten the three carriage and four tapered head bolts to 55 ft/lbs. (photo 19)

K. Mark the two tapered holes on the bottom of the frame rail and drill to ½”. Using a piece of mechanics wire, insert the nut

strip thru the existing hole in the outside frame rail and pull into location. (Photo 20)

L. Install one of the tapered head bolts into the open hole, pull the wire from the nut strip and install the second tapered head

bolt. Torque to 55 ft/lbs. (photo 21)

Photo # 14 Photo # 15

RI7330 Page 6 of 9

Photo#16 Photo#17

Photo#18 Photo#19

Photo#20 Photo#21

Step 5 – Rear arm and component installation

Rear arms

A. Prepare the rear of the vehicle for control arm and component installation by removing the following items: shocks,

sway bar links, coil springs, track bar, brake line brackets at the frame, e-brake cables at the body and the drivers side

upper and lower control arms.

B. Pre set the lower rear long arms to 41.5” center to center and install the coupler end into the frame brackets with the

supplied 9/16” bolt, flat and lock washers. Attach the rubber bushing end into the lower control arm mount on the axle

housing using the factory hardware. Do not tighten the rubber bushing until the vehicle is on the ground to avoid

bushing preload.

RI7330 Page 7 of 9

C. Set the upper arm to an initial setting of 17.5” center to center, install the coupler end at the mounting point on the

lower arm with the supplied ½” hardware and the other end at the upper mount on the axle using the factory

hardware. (photo 22)

D. Repeat steps A – C on the passenger side.

E. The upper arms may need to be to be readjusted after the installation is complete for proper pinion angle.

Photo # 22 Photo # 23

Rear track bar bracket and factory track bar

A. Place the new track bar bracket into the pocket of the factory bracket. Loosely install the 9/16” bolt thru the stock mounting

location from the front to back. This will keep the hardware from interfering with the lower bump stop pad.

B. Insert the two supplied ½” bolts with washers and nyloc nuts thru the cross member mounting point. Tighten to 60 ft/lbs.

C. Tighten the 9/16” bolt to 75 ft/lbs

D. Using the factory hardware, loosely install the factory track bar into the axle housing end then the upper track bar mount.

Again, use the factory hardware and install from the front to the back. (photo 23)

Rear coil springs and sway bar links

A. Using the factory spring isolator place the rear coils up into the upper mount and over the lower mount. Raise the axle into

place just enough to keep the coil spring from falling out.

B. Install the supplied links (RE1157). Install the driver side link to the inside of the sway bar and lower axle mounting point.

On the passenger side, install the link on the outside of the sway bar link and lower axle mount.

Rear brake lines and shocks

A. Remove and replace the rear brake lines with the included stainless steel brake lines. The lines are left and right specific and

when installed the 90 degree leader from the caliper should be leaning away from the tire. (photo 12)

B. Depending on what shocks have been purchased with the suspension kit it may be necessary to reuse the sleeves and bar

pins from the stock shocks. If this is necessary be sure to lubricate the sleeves or bar pins during removal and most

importantly during re-installation.

Fuel tank and exhaust

A. Reinstall the fuel tank in the reverse order of removal. Be sure that the hoses do not get bound on any frame rails or cross

members while raising the tank into position. Connect the wire harness and hose on the top of the tank before completely

raising the tank. (photo 24)

B. Route the e-brake cables below the fuel filler and breather hose so during suspension cycling the cables do not pull on the

fuel hoses. (photo 25)

C. Re-hang the factory exhaust system and tighten all clamps.

RI7330 Page 8 of 9

Photo # 24 Photo # 25

Step 6 - Final details, adjustments and drag link install

A. Install wheels, verify all coils are properly seated shocks installed and lower the vehicle.

B. Check the front track bar for axle center, adjust as necessary.

C. Tighten all control arm and track bar rubber bushing hardware. Use factory specs where factory bolts are used.

D. Properly bleed brake lines per factory manual and check for leaks and a firm pedal.

E. Manually disable the factory ESP system before the first test drive. (Refer to owners manual for the disable procedure) Note the

location of steering wheel while driving in a straight line and any driveline vibrations.

F. Install RE2610 drag link. See supplied instruction sheet for the front drag link (RE2610) for proper install (4.5” lifts only). Adjust

drag link to center the steering wheel. NOTE: Centering the steering wheel is highly critical for proper ESP function. Minimum

factory caster and maximum factory toe-in seems to work well with these front ends (see Troubleshooting as well).

G. Adjust upper control arms if necessary for proper front castor angle and rear pinion angle. NOTE: Shown below is a diagram of

proper pinion angle for a CV style drive shaft (see Troubleshooting as well).

H. Retighten all bolts after 50 miles and again after every off road excursion.

I. After all adjustments have been made, Rubicon Express recommends that your local Jeep dealership “flash” the computer to

adjust for proper tire size and ESP control settings. .

TROUBLESHOOTING

Rear driveline:

Acceleration vibration: Caused by the pinion being too high in relation to the transfer case output shaft. Adjust upper control arm to lower

pinion accordingly.

Deceleration vibration: Caused by the pinion being too low in relation to the transfer case output shaft. Adjust upper control arm to raise

pinion accordingly.

High speed wobble:

It is a condition where front tires will shimmy after hitting a bump. Avoid bias ply tires and wheels with excessive offset. Check for worn or

loose parts. In most cases a reduction of positive castor will eliminate this condition.

RI7330 Page 9 of 9

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