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
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