RE Slip Yoke Eliminator Kit NP231NP242 Post-1996.pdf

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

INSTALLATION INSTRUCTIONS FOR:

RE1807 SLIP YOKE ELIMINATOR KIT FOR TJ NP231 AND ‘96+ XJ

NP231 OR NP242 TRANSFER CASES

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

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:

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 drive shaft.

INSTALLATION OPTION 1 - Installation on vehicle w/o splitting

transfer case.

Installation Warning:

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.

KIT CONTENTS:

Remove drive shaft.

Measure and mark shaft so that 1-1/8” to 1-1/4” of splined

shaft will remain.

Cut output shaft with abrasive cutting wheel.

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

splines.

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

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

shaft 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.

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

Remove stock slip yoke if used as a guide.

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

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

HWC10040 Bag kit #14 including;

21/64 Drill bit

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

washer. Be sure to use thread lock.

3/8-24 Tap

3/8-24 X 1 HSC Bolt

Install RE1898 type flanged CV drive shaft using supplied

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

at pinion yoke.

3/8 Lock washer

5/16 Flat washer through hard

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

Grease u-joints and slip splines in drive shaft.

7/16-14 Nylock nut

Check transfer case fluid level.

Test drive and inspect for leaks.

Re-tighten bolts and re-grease drive shaft after first 100

miles.

REQUIRED TOOLS:

INSTALLATION OPTION 2 - Modifying shaft outside of transfer case.

Basic mechanics' wrenches

Circular saw & metal cutting blade

Hammer and center punch

Drill motor and high quality 3/16” drill bit

Hand tap handle

Cutting oil

Thread lock

Refer to factory manual for instructions on removing shaft

from transfer case.

Cut shaft so that 1-1/8” to 1-1/4” of splined shaft will remain

(use steps 3-4 of option 1 for reference).

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

steps 5-9 of option 1 for reference).

Reinstall shaft in transfer case.

Follow instructions in option 1 starting with #10.

RE1807A Page 1 of 1

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

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