Synergy 8009-30 - Jeep JK Front Axle Outer Shell Kit - Manual

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
PPM-8009 JK DANA 44 HD FRONT AXLE GUSSET
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.
• Please read these instructions carefully before you start, do not attempt if you do
not have the tools or skills required.
• This kit only works on a factory JK front Dana 44 axle housing
• This kit requires you to cut off all the factory axle brackets, careful cutting,
measuring and welding is involved, do not attempt if you do not have the skills to
properly perform this operation
• You will need a welder, cutting torch or plasma cutter, grinder, tape measure and
some sort of level or angle finder.
• For best results when welding to the cast diff housing, we recommend TIG
welding with stainless 312 rod or similar rod that is meant for cast iron welding to
mild steel. MIG and stick welding is also possible with the right rod, pre and post
heat.
1. Unpack all of the components and verify all the parts are there and are in good
condition. These are the parts that are included
• 8009-00 Short and long outer axle sleeves
• 8009-01 Track bar bracket and sway bar tab
• 8009-02 Lower control arm brackets (pair LH & RH)
• 8009-03 Lower shock mount brackets (pair LH & RH)
Optional parts
• 8009-07 Inner C gussets, 2 sets (4 pcs total)
• 8009-09 Axle truss
• 8009-10 Hydro assist ram bracket
2. Remove axle housing from the vehicle, you do not have to remove the gears &
locker, axle shafts or knuckles.
3. Using a plasma cutter or oxy-acetylene torch, cut off all of the suspension brackets
from the axle tubes, refer to the following steps for specific instructions.
4. Cut off the sway bar tabs and coil spring mounts on both sides. The coil spring
mounts will be re-used so try to just cut along the top edge of the weld bead on the