Installation Instructions
Contents
1. SYNERGY MFG 870 INDUSTRIAL WAY SAN LUIS OBISPO CA 805 242 0397 PPM 81 12 02 TJ LJ XJ ZJ INNER C GUSSET KIT GENERAL NOTES e These instructions are also available on our website www synergymfg com Check the website before you begin for any updated instructions and additional photos for your reference e The C gussets in this kit help to prevent the factory Inner C s from bending e These gussets can be installed with the axle still in the vehicle and with knuckles still attached e While not necessary we do suggest removing the knuckles and ball joints when installing C gussets as to prevent any heat damage to ball joints e Be sure to disconnect the ground cable from the battery prior to welding as to prevent electrical damage to the vehicle PARTS LIST e 2 811205 TJ LJ XJ ZJ LOWER C GUSSETS e 2 811206 TJ LJ XJ ZJ UPPER C GUSSETS 1L amp IR Parts Tools Needed to complete installation Basic simple hand tools 4 1 2 angle grinder with abrasive attachments to remove paint and metal from inner C s Some form of welder Mig is preferred but Tig or stick welding is acceptable Spray paint of desired color APPROXIMATE INSTALL TIME 4 6 HOURS INSTALLATION 1 Note we do recommend removing the balljoints from the housing prior to installing C gussets Excessive heat from welding can damage the plastic internals of a stock ball joint as well as the rubber dust boots Use discretion when welding 2 Ref2. er to your factory service manual for procedures on tearing the front axle down to the point of ball joint removal 3 Fit the C Gussets on the axle to see what areas need to be cleaned up in preparation for welding Mark if needed Note the orientation of the cut out for coil spring clearance The cut should face the front of the vehicle 4 a COIL SPRING 4 F 4 Clean the areas to be welded as shown 5 Once weld surfaces are prepared place upper C gussets in position There will likely be a slight gap around the ball joint area use a C clamp or vice grips to tighten the gusset in the proper welding position i NAD Ne 7 With upper C gussets fully welded on start on the lowers 8 First trim the sway bar end link mount to allow clearance for fitment A 9 Mark a cut line beginning at the end of the weld on the axle side straight out horizontally lt m CUT LINE 10 Cut along the marked line and grind smooth 11 Tack the lower C gusset on in several locations It should fit around the previously cut sway bar mount as shown below 12 Once tacked fully weld as shown in the picture below E 13 After welding clean off any weld burrs and paint the desired color to prevent corrosion 14 Refer to your factory service manual to reassemble the front axle Installation is Complete
Download Pdf Manuals
Related Search