Synergy 8569-03 - Dodge 2003-2012 AAM 9-1/4 Front Axle Truss Kit - Manual

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
8569-03 DODGE FRONT AAM 9-1/4” TRUSS KIT
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 beginning, do not attempt to install if you do not have the
tools or skills required.

**Note** installation of truss plates involved optional welding to cast housing center section. This
should be performed by an experienced welder using methods described in these instructions.
 For best results when welding to the cast diff housing, we recommend Tig welding with stainless
312 rod or similar rod that’s is meant for cast iron welding to mild steel. MIG and stick welding
is possible with the right rod used with pre and post heat.

This truss tube is compatible with all axle housings from 2003-2012

This truss kit is designed to be used in conjunction with Synergy parts: 8561 / 8569 Dodge AAM Front
Axle C-gusset kit
PARTS LIST:
 (1) 856903-01 Truss Plate, Long Side
 (1) 856903-02 Truss Plate, Short Side
 (1) 856903-03 Lower Truss Tube
Parts / Tools Needed to complete installation:

Basic simple hand tools.

4-1/2” angle grinder with cut off wheel and abrasive attachments to remove paint from inner C’s

Some form of welder. Tig is preferred for welding to cast center section, but Mig or stick can be used
with proper pre-heat and post-heating methods.
APPROXIMATE INSTALL TIME: 4-6 HOURS
INSTALLATION:
1) Installation can be done with axle still installed in vehicle, however welding becomes more difficult. In
these instructions, the axle has been removed from vehicle. Follow service manual for axle removal if
desired.
2) After installing C-gussets. (See 8561 / 8569 instructions for C-gusset installation) Begin by fitting axle
truss tube as shown below. Truss tube should be centered front to back on bottom of C-gussets and fit
behind front lip of cast center section.