Synergy 8023-X - Jeep JK Synergy Stage 3 Suspension System - Manual (Page 16)

• Once the shock bracket position is determined you can cut the bottom of the lower
control arm bracket off flush with the bottom of the shock brackets. Remove the
shock brackets and shocks. A sawzall works well for this, you can cut off the whole
lower section of the bracket with one cut. Do not cut off the anti-sway bar link tabs.
• Install the lower shock relocation brackets, use the supplied 3/8 x 1” bolts to attach
the shock bracket to the rear lower control arm bracket. Use flat washers under the
bolt heads and use flange nuts on the inside of the lower control arm bracket. The
lower nuts are easy to get to but the uppers can be difficult, the easy way is to put the
flange nut in the end of a box end wrench and slide the nut up the inside of the lower
control arm bracket and align it with the hole. Use the factory anti-sway bar link
bolts to attach the side of the bracket to the anti-sway bar link tabs. Insert these bolts
from the outside so the nut is against the shock bracket. Torque the lower sway bar
bolts to 75 ft-lbs
21. INSTALL COIL SPRINGS, SHOCKS AND SWAY BAR LINKS
• Install the new coil springs. If you have rotated the pinion up for a CV driveline, we
recommend that you cut, rotate and re-weld the lower coil spring mount on the axle to
align level or purchase coil spring angled wedges.
• Jack the axle up enough to install the shocks using the original hardware, torque the
upper bar pin bolts to 37 ft-lbs and the lower bolt and nut to 56 ft-lbs.
• Make sure the sway bar links are adjusted to the same length and tighten the jam nut.
Install the upper end of the sway bar links to the sway bar. If the rod end stud does
not fit through the sway bar you will have to enlarge the holes with a ½” drill.
Tighten the nut to 66 ft-lbs
22. FINAL INSTALLATION STEPS
• Jack the rear axle up enough to install the tires and wheels.
• Remove the jack stands under the frame and lower the jeep to the ground.
• Attach the track bar to the new track bar relocation bracket using the factory nut and
bolt. If the track bar does not line up with the hole you can have someone push the
back of vehicle from side to side to align the track bar bushing to the hole in the
bracket.
• Now that he vehicle is sitting at ride height on level ground you can do the final
fastener torque
• Torque the front and rear lower control arm bolts to 125 ft-lbs and pinch bolts to 80
ft-lbs
• Torque the front upper control arm bolts to 90 ft-lbs and pinch bolts to 50 ft-lbs
• Torque the front and rear track bar bolts to 125 ft-lbs
• Torque the lug nuts to 85-125 ft-lbs.
• Bleed the brake system if you have not already done it.
• If you have rotated the pinion up we recommend that you add one addition quart of
gear lube in the rear differential to supply the front pinion bearing with gear lube.
You can buy an aftermarket diff cover with a higher fill plug or unscrew the breather
fitting in the axle tube and add the additional gear lube through there.