Synergy 5022-02 - Jeep JK Frame Side RLCA Gusset Kit - Manual

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
5022-02 JEEP JK REAR LOWER CONTROL ARM GUSSETS
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.

This is a weld on gusset kit and should be installed by an experienced welder.

We recommend installing one side at a time.
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**Note** Gas tank removal will be required if 502202-03 Inner gusset plate is desired to be installed on
the passenger side. Steps 9-21 will cover gas tank removal.
PARTS LIST:

PART NUMBER – PART DECRIPTION
 (2) 502202-01 Rear Lower Control Arm Outer Gusset Plate
 (2) 502202-02 Rear Upper Control Arm Gusset Plate
 (2) 502202-03 Rear Lower Control Arm Inner Gusset Plate
Parts / Tools Needed to complete installation:

Basic simple hand tools.
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4-1/2” angle grinder with sanding disc, or 3” air sander with sanding disc to prep surfaces for welding
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Welder. Mig is preferred, but stick or Tig are acceptable as well.
INSTALLATION:
1) Installation can be done with the vehicle on the ground and control arms in place, however we advise to
remove control arms as to not melt suspension joint bushings during welding.
2) Start on the driver’s side. Begin by test fitting gusset plates onto the vehicle and marking which areas
need to be prepped for welding. The 502202-01 RLCA Outer Gusset Plate should butt up to the rear
body mount as shown in image 2.1 and 2.2 below.