Synergy 8240 - Jeep XJ Rear Spring Hanger Bracket - Manual

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
PPM-8240 JEEP XJ REAR SPRING HANGER BRACKET
Version 1.1
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 this suspension kit requires some major cutting, grinding, drilling and
optional welding.

You will need basic hand tools, a drill with a 3/8” drill bit, a grinder with cut off wheel or
sawzall, floor jack or automobile lift, and two sturdy jack stands to complete this
installation. A spot weld cutter will make removal of the stock spring hanger much
easier. Part number: 4096A11 on
www.mcmaster.com works well for this installation.
1) Unpack the brackets and hardware from the package and verify that all parts are present.
PPM-8240 Parts List

20: 3/8-16 x 1” Bolts

20: 3/8-16 Top Lock Nuts
 40: 3/8” flat washers

2: 9/16-18 x 4.5” Bolts

2: 9/16-18 Top Lock Nuts
 2: 9/16” flat washers

2: PPM-8240 Rear Spring Hangers.
2) Begin by jacking the rear of the vehicle up by placing a floor jack under the center of the diff
and securely support the vehicle using jackstands to take the weight of the vehicle off the rear
suspension. Leave the jack under the rear axle for the duration of the installation process.
a. Remove the wheels, U-bolts, rear spring to shackle bolt, and forward spring to
spring hanger bolt and remove the leaf springs.
b. To prevent damage to the interior of the vehicle, lift up the carpet in the rear
passenger footwell as drilling into the vehicle will take place here. The bottom of
the rear seat, and carpet underneath it will also need to be removed to access some
of the holes drilled and prevent damage to the carpet.
3) With the rear springs removed, removal of the forward spring hanger can begin. Note that
the forward spring hanger is spot welded to the vehicle in many places. It is not necessary to
remove every part of the bracket and is not recommended since it is difficult to do without
damaging the unibody around the hanger.