Synergy 8024-30/8024-40 - JK Synergy Stage 4 Long Arm System - Manual (Page 27)

whole lower section of the bracket with one cut. Do not cut off the anti-sway bar
link tabs.
h) 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
23. INSTALL COIL SPRINGS, SHOCKS AND SWAY BAR LINKS
b) 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.
c) 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.
d) 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
21. FINAL INSTALLATION STEPS
a) Jack the rear axle up enough to install the tires and wheels.
b) Remove the jack stands under the frame and lower the jeep to the ground.
c) 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.
d) Now that he vehicle is sitting at ride height on level ground you can do the final
fastener torque
e) Torque the front and rear lower control arm bolts to 125 ft-lbs and pinch bolts to
50 ft-lbs
f) Torque the front upper control arm bolts to 90 ft-lbs and pinch bolts to 50 ft-lbs
g) Torque the front and rear track bar bolts to 125 ft-lbs
h) Torque the lug nuts to 85-125 ft-lbs.
i) Bleed the brake system if you have not already done it.
j) 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.
k) Adjust the draglink to center the steering wheel by using the adjuster sleeve on the
passenger side tie rod end (steering knuckle end). This requires a 1 ¼” wrench.
Tighten the pinch bolt to 50 ft-lbs.
l) If the steering wheel is not centered the ESP light will come on, so make sure you
adjust the draglink so the steering wheel is perfectly centered. This is can
accomplished by test driving and making the necessary adjustments. When
driving in a strait line take note of which way the steering wheel needs to turn to
be centered. If the steering wheel needs to turn right to be centered, shorten the