Rubicon Express JL7141 1.5-inch/2.5-inch 4-Door Suspension Lift Kit Instruction Manual

1. Introduction

This manual provides detailed instructions for the proper installation and maintenance of the Rubicon Express JL7141 1.5-inch/2.5-inch 4-Door Suspension Lift Kit for the 2018 Jeep JL Wrangler. This system is designed to enhance off-road performance and allow for larger tire fitment without requiring extensive modifications to driveshafts, exhaust, or brake lines. It aims to increase ground clearance and extend wheel travel.

2. Safety Information

Always prioritize safety during installation. It is recommended that installation be performed by a certified professional. If you choose to install this kit yourself, ensure you have the necessary tools, experience, and a safe working environment. Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves. Never work under a vehicle supported only by a jack. Use jack stands or a vehicle lift. Disconnect the vehicle's battery before beginning work. Refer to your vehicle's factory service manual for additional safety precautions and torque specifications.

3. Package Contents

Verify all components are present before beginning installation. The Rubicon Express JL7141 kit includes:

• Front Coil Springs
• Rear Coil Springs
• Front Sway Bar Links
• Rear Sway Bar Links
• Bump Stop Extensions/Pads
• Hardware Kit (bolts, nuts, washers)

4. Tools Required

The following tools are generally required for installation:

• Metric Sockets and Open-End Wrenches (various sizes, including 6mm, 10mm, 13mm, 15mm, 18mm, 21mm, 24mm)
• Torque Wrench
• Locking Pliers (x2)
• Air Gun (optional, for faster bolt removal)
• Vehicle Lift or Jack and Jack Stands
• Wheel Chocks
• General Mechanics Tools (screwdrivers, pry bars, etc.)

5. Installation Instructions

This section outlines the general steps for installing the suspension lift kit. Always refer to the specific instructions provided with your kit for precise details and torque specifications.

5.1. Preparation

1. Park the vehicle on a flat, level surface. Engage the parking brake and chock the rear wheels.
2. Loosen the lug nuts on all wheels.
3. Raise the vehicle using a lift or jack stands, ensuring it is securely supported.
4. Remove all wheels and tires.

5.2. Front Suspension Installation

1. Disconnect the front sway bar links from the axle and sway bar.
2. Remove the bolt connecting the front track bar to the axle.
3. Disconnect the brake lines from their brackets to prevent stretching when the axle is lowered.
4. Disconnect the axle actuator plug and any zip ties or plastic clips connecting lines to the upper control arm.
5. Loosen, but do not remove, the control arm bolts.
6. Support the front axle with a jack. Remove the bolt connecting the lower end of the front shocks to the axle.
7. Carefully lower the axle until the factory coil springs are loose and can be removed. Be mindful of all lines and wires to avoid stretching.
8. Install the new Rubicon Express front coil springs. Ensure the bottom of the spring aligns with the spring index.
9. Install the front bump stop strike pads. Use the provided tool to tighten the bolt and nut for the bump stop.
10. Raise the axle to reconnect the front shocks. Torque the shock bolts to factory specifications.
11. Install the new front sway bar links.
12. Reconnect the breather hose, axle actuator plug, and any plastic retainers.

5.3. Rear Suspension Installation

1. Loosen, but do not remove, the rear control arm bolts.
2. Remove the emergency brake cable bracket located on the vehicle body.
3. Disconnect the emergency brake lines from the axle and the e-brake eyelet. Feed the cables over the cross member and fuel lines.
4. Disconnect the track bar at the axle.
5. Support the rear axle with a jack. Remove the bolts connecting the lower end of the rear shocks to the axle.
6. Remove the rear sway bar links and move the sway bar out of the way.
7. Detach the brake line bracket from the axle.
8. Carefully lower the axle and remove the factory coil springs and spring isolators.
9. Install the new Rubicon Express rear coil springs with the factory spring isolators. Ensure the spring end matches the spring index. Verify correct driver/passenger side installation by checking the part number on the spring.
10. Install the rear bump stop strike pads by placing the mounting plate onto the axle bracket and securing it with the provided hardware.
11. Raise the axle to reconnect the rear shocks. Torque the shock bolts to factory specifications.
12. Install the new rear sway bar links. Ensure the sway bar link is installed upside down with the swivel stud on the axle end to prevent contact with the frame during articulation.
13. Reconnect the brake line brackets.
14. Insert the track bar bolt, but do not tighten until the vehicle is back on the ground.
15. Reattach the emergency brake cables to the axle and then to the eyelet. Ensure cables do not hang below the axle.

5.4. Final Steps

1. Reinstall the wheels and tires. Torque lug nuts to factory specifications.
2. Lower the vehicle to the ground.
3. With the vehicle on the ground, torque all control arm bolts and track bar bolts to factory specifications.
4. Perform a full alignment of the vehicle.

6. Specifications

7. Maintenance

Regular inspection of all suspension components is crucial for safety and performance. Check all bolts and nuts for proper torque after the first 500 miles of installation and periodically thereafter. Inspect coil springs, sway bar links, and bump stops for any signs of wear, damage, or corrosion. Clean components as needed, especially after off-road use, to prevent buildup of dirt and debris.

8. Troubleshooting

If you encounter any issues after installation, consider the following:

• Unusual Noises: Check all fasteners for proper torque. Inspect components for contact with other parts of the vehicle.
• Uneven Ride Height: Verify that the correct springs are installed on the appropriate sides (driver vs. passenger, if applicable) and that all components are seated correctly. Ensure tire pressures are even.
• Poor Handling: A professional alignment is critical after any suspension modification. Ensure all control arm and track bar bolts are torqued while the vehicle is at ride height.
• Tire Rubbing: Re-check bump stop installation and consider additional bump stop shims if necessary, referring to tire clearance guides.

For persistent issues, consult a qualified automotive technician or contact Rubicon Express customer support.

9. Warranty and Support

For information regarding product warranty, returns, or technical support, please refer to the official Rubicon Express website or contact their customer service department directly. Keep your proof of purchase for any warranty claims.