SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
PPM-5011-03 AIR BUMP STOP BRACKET KIT
INSTALLATION
Version 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 these brackets requires the use of PPM-5011 Coil over brackets
and coil over shocks.
• The installation of this bracket requires the complete removal of the stock shock
and coil mounts on the frame and axle. A plasma cutter or oxy-acetylene torch
works but you can also use a sawz-all and cut off wheel. The new bracket must
be welded to the frame and axle tube. An experienced fabricator/welder is
recommended to properly install this bracket.
1. Refer to complete PPM-5011 coil over instructions for bracket removal and
installation of the rest of the required components
2. Tack weld the air bump mounting brackets into place. Position the back of the air
bump mounting bracket against the front of the shock brackets. The air bump
mounting brackets are left and right specific; the side with the diagonal bend is the
rear of the bracket. Put that side against the shock bracket.
a) Move the air bump bracket all the way back so it is against the front of the shock
bracket.
b) Make sure the front of the air bump mount is just behind the steering box
mounting tubes.
c) Move the air bump mounting bracket all the way up so the bottom fingers are up
against the bottom of the frame.
3. If you are not using air bumps and purchased the budget bump kit, cut the bump stop
cup from the stock upper coil mount. Be careful to just cut the weld and leave the
bottom of the cup intact. You will need a 3/8 x 1 coarse thread bolt and washer to
attach the cup to budget bump.
Install the snap ring in the lowest groove; this will give you the same collapsed length as
an air bump.
4. Now that all the shock and air bump brackets are tack welded into place, we
recommend that you bolt the shocks into place without the coil springs and cycle the
suspension to check that every thing clears. Make sure that the air bumps bottom out
before the shocks do. Also check for brake line, driveline and steering linkage overextension.
5. If everything fits and clears well, weld the brackets to the frame and axle mounts:
a) Weld all edges that the coil over shock bracket and air bump bracket contact the
frame. Weld both inner vertical seams and the top of the frame between the shock
bracket and frame. Weld the rear vertical seam above and below the brake line
bracket hole. Weld the front, top and bottom of the air bump bracket. Also weld
the back of the air bump mount to the front of the shock bracket.
b) Weld all edges that the lower shock bracket contacts the axle tube, front, bottom
and both sides.
6. Clean the welds and paint the new brackets and frame.
7. Assemble the front suspension and coil over shocks. Torque the ½” shock bolts to 80
ft-lbs and the bump stop pinch bolts to 10 ft-lbs.
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