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.
Note: It is recommended that CV rear driveshaft be used for best performance – see general vibration in troubleshooting before proceeding.
1. Raise vehicle and support with stands.
2. Remove wheels.
3. Remove front shocks.
4. Remove front sway bar end links.
5. Remove front spring retainer clamps.
6. Disconnect front track bar. Disconnecting steering at pitman arm makes axle droop out farther.
7. Remove front springs. Spring compressors may be helpful.
8. Support the front axle with jack stands.
9. Remove factory lower control arms.
10. Remove factory brake lines and replace with supplied lines. Some require positioning the block and line vertically at the caliper. Watch line routing, use angle brackets and e-clips.
11. Drill 5/16” hole in center of lower spring pads.
12. Use self-tapping bolt through bump stop extension spacer to cut threads in lower spring pad. Remove bolt and spacer, it will be installed with the spring.
13. If so equipped, use factory eccentric hardware at front axle lower arm mount. If not, use the supplied 9/16” bolt.
14. Install the lower control arms with the rubber bushing at the frame bracket. Use the factory hardware at the bushing end (don’t fully tighten until vehicle is back on the ground). The super-flex joint will be installed at the axle with the offset tube being mounted as low as possible (zerk on top – see Photo 1). Use supplied hardware for the Superflex end.
15. Install the front springs (RE1363) with the pig-tail at the top and the 2” bump stop extension inside of the coil. Coil spring compressors may be useful. Once the coil spring is in place, thread the bump stop bolt into the lower spring pad (refer to step #12). Rotate the coil to index the spring with lower coil cup.
16. Install the spring retainer clamp removed in step #5.
17. Install longer front shocks. Bar pins may need to be put through the bottom shock eyes (use light grease).
18. Install sway bar quick disconnects per instructions supplied with disconnects (see Photo 2 for typical installation).
19. Re-drill front track bar axle bracket over toward drivers side ¾”, center-to- center (or install optional adjustable front track bar). Reconnect track bar at new hole.
20. Remove the rear shocks.
21. Remove the rear sway bar end links.
22. Support the rear axle.
23. Disconnect rear track bar at axle.
24. Remove the factory lower control arms.
25. Remove the rear springs.
26. Remove the plastic dust shield that covers the bolt securing the rear track bar to the mount on the axle housing and discard.
27. Remove the Torx head bolt (t55) and disconnect axle end of track bar. If not done previously
28. 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).
29. 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.
30. Install the 5/16” hardware in the holes drilled in step #29. If required, use supplied horseshoe shim to take up space between bracket and axle mount at top 5/16” bolt.
31. Install the track bar in the track bar bracket using the Torx bolt removed in step #27. It may be easier to do this later with weight on the vehicle.
32. Install the lower control arms with the rubber bushing at the unibody and super flex end at the axle. The offset tube should be mounted as low as possible (zerk on top - see Photo 1). Use the factory hardware at the uni-body and supplied bolt at the axle mount (don’t fully tighten until vehicle is back on the ground).
33. If installing optional upper control arms, set length 3/4” longer than stock for a CV drive shaft (1/4” if trying to use std shaft) as a good starting point (see general vibration in troubleshooting). Install the upper control arms using the factory hardware (don’t fully tighten until vehicle is back on the ground). Super flex end should be at axle with zerk on top (see Photo 4).
34. If installing optional cam bolts, install per instructions included with cam bolts (see General Vibration in Troubleshooting).
35. Remove the rubber insert from the rear bump stop. Remove the bump stop cup. Place the 1-1/2" bump stop extension between the bump stop cup and the frame using the supplied longer metric hardware.
36. Install springs. Spring compressors may be helpful.
37. Install replacement sway bar end links.
38. Install longer rear shocks.
39. If using, install transfer case drop kit by supporting one side of transfer case with floor jack. Remove hardware from one side of crossmember. Install spacers and new hardware. Tighten to 55 ft./lbs. Repeat on opposite side. NOTE: If used on a vehicle with a 6 speed manual transmission contact between the shifter and body may occur in 2nd, 4th, and Reverse. In this case it will be necessary to remove the shift boot to verify for clearance and possibly modify the body to allow a minimum of 1/8” clearance between the shifter and the body.
40. Install all tires.
41. Thoroughly bleed brake lines and check for leaks.
42. Double-check all nuts and bolts to factory torque specs.
43. Test drive and note location of steering wheel. Adjust drag link to center steering wheel.
44. Align vehicle as soon as practical. A good rule of thumb is minimum factory caster and maximum factory toe-in.
45. Recheck all bolts after 50 miles and again after every off-road excursion.