Synergy 8012-01 - JK, TJ/LJ, XJ, ZJ D30/44 Inner Axle Sleeve Kit - Manual

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
PPM-8012-01 / 8012-09 / 5901-30 / 5901-44
JEEP DANA 30/44 INNER AXLE SLEEVE
Version 3.0
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.

The installation of the inner axle sleeves requires removal of the wheels, brakes,
axle shafts and axle housing assembly.

Installation of the sleeves requires drilling 1/2” holes at various places on the axle
housing.

A competent welder is needed for completing the plug welds and circular welds
around the axle housing tube for proper installation.

It is recommended to remove the axle housing completely; this will make drilling
and welding much easier.

It is not necessary to remove the differential and gears or even drain the oil. Just
be careful to not let metal chips in the housing when drilling the holes for the plug
welds. Be careful to keep the housing level so gear oil does not leak out.

The following instructions cover installation on a D30 / 44 JK housing.
Installation will be similar on a TJ housing.
1. Start by placing the front of the vehicle on jack stands placed on the front portion of
the frame or on an automotive lift.
2. Remove the front wheels.
3. Remove the brake caliper mounting bracket from knuckle using a 21mm socket and
remove the brake calipers, hang or tie the brake calipers to the frame out of the way.
4. Remove the brake rotors.
5. Remove outer axle nut using a 35mm socket.
6. Remove the ABS sensor from the unit bearing using an 8mm allen wrench.
7. Remove the 3 unit bearing bolts from the inside of the knuckle using a 13mm 12
point socket
8. Remove the unit bearings and axle shafts.
9. Remove the shocks, sway bar links, coil springs, locker actuator connectors,
driveshaft, draglink, track bar and all control arms at the housing. This will allow for
removal of the complete housing.
10. Place the axle housing on jack stands on the ground or work bench for the drilling and
welding process.
11. On the short side of the axle housing; mark the holes shown in Figure 1 and repeat the
pattern for the back/underside of the housing.