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ManualsBrandsSynergy ManualsCar5051 - Front 3 Link Kit for Jeep TJ

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397

5051 - SYNERGY SUSPENSION UNIVERSAL FRONT

3-LINK KIT

Version 1.0

GENERAL NOTES:

• 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.

• These instructions include only the link suspension kit, you will need to

accommodate steering, spring and shock mounts in addition

• This is a universal kit and will likely require modifications to these components to

fit your application correctly

• The installation of this suspension kit requires extensive cutting, grinding and

fabrication. Many of the major suspension brackets on the frame will need to be

cut off and ground smooth. A plasma cutter or oxy-acetylene torch works best

but you can also use a grinder with a cut off wheel.

• You will need basic hand tools, MIG welder a grinder with cut off wheel or

sawzall, floor jack or automobile lift, and two sturdy jack stands to complete this

installation.

1. Unpack the suspension components from the boxes, verify that all parts are intact and

in good condition.

2. Read all the following steps before beginning installation. If you do not have the

proper tools or ability to install the components properly do not attempt installation.

Find a creditable, local shop to do the installation work.

3. Take some baseline measurements of your existing suspension so you know what you

had, measure the distance from the axle to the frame at ride height, axle to the ground,

and axle location front to back.

4. Make a plan and take notes of what you want to change, i.e. move the axle forward

+2 is common.

5. Tack weld everything, do not finish weld any component until you have cycled the

suspension and checked that everything clears adequately.

FRAME LINK BRACKETS

6. Use a floor jack under the center of front axle to lift the tires off the ground. Place

jack stands under each side of the front portion of the frame rails to support the

weight of the vehicle. Raise or lower the floor jack under the front axle to remove

and install suspension components.

7. Remove the front suspension components and the entire front axle assembly

Summary of content (16 pages)

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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 5051 - SYNERGY SUSPENSION UNIVERSAL FRONT 3-LINK KIT Version 1.0 GENERAL NOTES: • 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.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 8. Cut off any suspension bracket on the frame that you will not be using, i.e. lower control arm brackets, shock mount, spring mounts, track bar brackets, leaf spring hangers, etc 9. Position and clamp the new front frame control arm brackets on the frame. The front to back location is entirely up to you, on a TJ or YJ, the front tub body mount generally is where it goes, but you can go as far back to the T-case skid plate.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 10. Mark the bracket where the top edge of the frame is.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 11. Remove the control arm bracket and cut at the line.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 12. Reposition the control arm bracket to the frame and tack weld the upper plate on. 13. Remove the control arm bracket again and weld the top plate on.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 14. Decide which side you want the upper control arm on. It usually goes on the side that the drive shaft is on. Driver side for a TJ or YJ. Weld the upper control arm top plate and gusset as shown below. There of two of these brackets included, you can use both and make a triangulated 4-link. The opposite side frame bracket without the upper control arm gets the 2 vertical gussets.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 15. Reinstall and tack weld the control arm brackets on the frame. Double check the front to back location and make sure they are the same side to side. AXLE LINK BRACKETS 16. Cut off all or any unwanted suspension brackets from the axle housing. Use a grinder with a cut off wheel, plasma cutter or oxy-acetylene torch. Grind the welds smooth. 17.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 19. Mock up the single upper control arm mount (may require fabrication or purchase of an axle bridge for over the diff housing). Do not weld entirely to a cast diff housing, it will not hold. The side to side location is usually pretty tight so you may want to wait until you place the axle back in the vehicle to finalize this mount. LOWER CONTROL ARMS 20. Position the axle housing back under the vehicle on jack stands.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 jam nuts into the threaded bungs. Only leave a couple of threads exposed past the jam nuts. Measure from the center of rod end to the step on the threaded bung were the tube is to be welded. Subtract two times this dimension from your center to center measurement and this is the cut length of your tube. 22. Cut the lower control arm tubing to the length calculated above and tack weld the threaded bungs in. 23.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 26. You may want to raise the front axle up to where you think full bump is to check clearance for the upper control arm. Once you have determined a upper control arm side to side location you can fabricate the upper control arm bracket.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 27. Measure center to center of the upper control arm bracket, cut and tack weld the tube for the upper control arm and install in the vehicle. TRACK BAR 28. Position the axle track bar mount on the axle. This bracket typically goes as far out to the knuckle as possible. Usually up against the inner C weld. This height works well for most high steer configurations, but can be trimmed to make it lower if needed.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 29. Determine the mounting location for the frame mount track bar bracket. The track bar needs to be parallel to the drag link so you may need to trim the bracket to mount higher if needed. Tack weld the bracket to the frame.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 30. Assemble the bushing at the frame end and rod end at the axle end of the track bar. 31. Cut the track bar tube to the appropriate length, you may need to put a bend in the track bar to clear the differential, cycle the suspension to check for proper clearance. 32. Tack weld the track bar tubing to the frame bushing and rod end tube bung. FINAL CHECK AND ASSEMBLY 33.
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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 33. Cycle the suspension and double check that everything clears satisfactorily. 34. Remove the control arms, axle housing and weld: Weld the axle housing control arms and track bar mount Install the gussets and weld the frame track bar mount Weld the frame control arm brackets to the frame Remove the rod ends from the control arms and weld the tube bungs Remove the track bar bushing and rod ends and weld the bushing tube and tube bung 35.