Synergy 5000 User Manual

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA [phone]

PPM-5000 SYNERGY SUSPENSION JEEP TJ FRONT
COILOVER BRACKET KIT

Version 1

GENERAL NOTES:

Requirements:
Fabrication and welding skills, grinder with cut off wheel, and a welder. A plasma cutter
(or cutting torch) and other fabrication tools will make the install easier. This kit requires
cutting and welding of the frame.

This kit requires cutting off part of the factory shock mounting bracket and parts of the
inner fender. You will also have to weld the new bracket in place. Some under hood
components may need to be relocated or repositioned. This kit is designed to use a 2.0
Fox or Sway-A-Way 12" Travel shock with a 3" lower bumpstop spacer (not included in
the kit). A 14" travel shock can be used but up travel will be sacrificed.

1. Remove the front tires, wheels, shocks, springs, and any under hook components
that may interfere with installation.

Figure 1 Mark the stock shock mount to be cut

2. Mark the rear and the top of the stock shock mount as shown in the picture
(Figure 1).

Figure 2 - The finished cut should like this

Note: DO NOT cut the bump stop mount off unless you are upgrading to our
hydraulic bump stop kit (PPM -5002).

3. Position the new shock mount bracket. This will provide a rough guide for cutting
the inner fender. The hole only needs to be large enough to fit the shock mount. If
your inner fender has been removed, ignore this step. See Figure 3

Figure 3

4. Clean off any paint around the edge of the shock mount where you will be
welding. Clamp the shock mount in position. Bolt the over-engine cross bar to the