RE Slip Yoke Eliminator Kit NP231 Pre-1996.pdf

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

INSTALLATION INSTRUCTIONS FOR:

RE1801 SLIP YOKE ELIMINATOR KIT FOR YJ NP231 AND PRE ‘96 XJ

NP231, NP242 or NP207* TRANSFER CASES

( * This kit will only work on an NP207 with the addition of an RE1802 bearing spacer)

Safety Warning:

Prior to installation please read both installation options and decide

which option is right for you. The output flange in this kit is designed for

use with an RE1898 type CV driveshaft.

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 OPTION 1 - Installation on vehicle w/o splitting

transfer case.

Remove drive shaft.

Remove tailcone section of transfer case.

Installation Warning:

Use duct tape or equivalent to seal bearing surface from

contact with debris.

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.

Measure and mark shaft so that 1-1/4” of splined shaft will

remain for NP231’s and NP242’s, and 1-1/2” for NP207’s.

Cut output shaft with abrasive cutting wheel.

Grind end of shaft square, and chamfer and de-burr the

splines.

Using drill and 3/16” drill bit, start pilot hole in end of shaft.

It may be helpful to remove the stock slip yoke from the

driveshaft and use it as a guide. To do this, first drill a 3 /16”

pilot hole centered at the dimple in the end cap of the slip

yoke. Install slip yoke onto shaft and drill a 3/16” hole, 1-

1/4” deep into the shaft.

KIT CONTENTS:

DS 2-70-18X u-joint strap kit

Next, bore out 3/16” hole with supplied 21/64” size drill bit.

Remove stock slip yoke if used as a guide.

FED #473317 seal

RM11500 SYE bearing/seal flange

Use supplied tap to cut threads in output shaft. Use cutting

oil while cutting threads and keep tap clean by backing it out

often. Use caution to not force the tap.

RM11510 4-bolt SYE CV output flange

M10-1.5 x 20 Allen bolts

HWC10040 Bag kit #14 including;

Install oil seal in the bearing/seal flange. Use care not to

damage seal.

21/64 Drill bit

3/8-24 Tap

Apply thin bead of RTV silicone to bearing side of flange.

3/8-24 X 1 HSC Bolt

Remove tape from transfer case and clean surface. If

installing kit on an NP207, install RE1802 bearing spacer

before seal flange. Push into housing against bearing with

small step pointing outward.

3/8 Lock washer

5/16 Flat washer through hard

7/16-14 X 1-1/2 HSC Bolt

7/16-14 Nylock nut

Install bearing/seal flange with supplied M10x20 Allen bolts.

Optional RE1802 NP207 bearing spacer (sold separately)

Apply silicone sealer to splines of new output flange. Be sure

enough sealer is applied to get back into the inside corner

where the splines meet the end washer.

REQUIRED TOOLS:

Install output flange using supplied 3/8”-24 bolt and lock

washer. Be sure to use thread lock.

Basic mechanics' wrenches

Install RE1898 type flanged CV driveshaft using supplied

7/16” nuts and bolts at flange, and supplied u-joint strap kit

at pinion yoke.

Circular saw & metal cutting blade

Hammer and center punch

Drill motor and high quality 3/16” drill bit

Grease u-joints and slip splines in driveshaft.

Hand tap handle

Check transfer case fluid level.

Cutting oil

Test drive and inspect for leaks.

Silicone sealer and thread lock

Re-tighten bolts and re-grease driveshaft after first 100 miles.

INSTALLATION:

RE1801-1802A Page 1 of 1

Center punch shaft to ensure drill starts in center of shaft.

INSTALLATION OPTION 2 - Modifying shaft outside of transfer

case.

Cut shaft so that 1-1/4” of splined shaft will remain for

NP231’s and NP242’s, and 1-1/2” for NP207’s (use steps 5-6

of Option 1 for reference).

Refer to factory manual for instructions on removing shaft

from transfer case.

Drill and tap the shaft to accept supplied 3/8”-24 bolt (use

steps 7-11 of Option 1 for reference).

Reinstall shaft in transfer case.

Follow instructions in option 1 starting with #12.

RE1801-1802A Page 2 of 2

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