Synergy 5012 User Manual

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

INSTALLATION INSTRUCTIONS

PPM-5012 JEEP TJ/YJ/CJ

UNIVERSAL SHOCK HOOP

GENERAL NOTES:

• These instructions are also available on our website at www.synergymfg.com

Check the website for any updated instructions and additional photos for
reference.

• Cutting and grinding of stock suspension components is required for installation.

• A welder and cutting tools will be needed to install kit.

• Note: the pictures and steps in these instructions were done on a CJ frame without

the body on it. Installation will vary slightly depending on shock configuration,
axle location and vehicle year / model.

• These instructions cover the installation of the shock hoops; they do not cover

removal of stock suspension components as this is a universal kit to be used on a
wide variety of vehicles.

HOOPS

1) Before beginning installation of PPM-5012 shock hoop kit, be sure to determine
desired axle placement and all unnecessary stock suspension components on the
frame have been removed to allow the shock hoops to be installed.

2) It is best to set up shock hoops with the suspension at full bump.

a. Set desired caster for ride height and then proceed to bring suspension to

full bump.

3) With lower shock mount position approximately determined, (i.e. on top of axle,
behind axle, on axle centerline, etc.) Position the fully bottomed out shock and
measure to determine the necessary height of main hoop.

a. Cut ends of hoop down accordingly to achieve proper shock hoop height.

Note – shock hoop frame pads are angled out at 12 degrees so that cuts to
the ends of shock hoop can be made straight for ease of installation.

b. Once satisfied with shock hoop height and angle, tack frame pads and

hoops into place. Note – it’s probably best for clearance issues to mount
the limit strap frame pad towards the rear and the dimple died pad towards
the front.

4) With hoops securely tacked, determine upper and lower shock tab placement and tack
into place.

a. Set suspension and shock at full bump with lower shock mount floating in

approximate position, and then determine upper shock tab location on
hoop and tack into place.

b. Bring suspension to ride height and tack lower shock mount into place.

Mount it so there is little to no misalignment in the rod end at ride height.
This should prevent binding of rod end bearing as the suspension cycles
through its complete range of travel.

5) Cycle and articulate suspension to ensure there is no binding or interference issues.

Installed shock hoop on passenger side. Note; only rear frame pad was used due to space

issues on driver’s side with trackbar mount.

CROSS BAR

6) To start, tack tube flanges to notched tube stubs.

a. Bolt second set of tube flanges to the ones tacked to notched tube stubs.
b. Hold tube stubs in desired location to determine how much material (if

any) will need to be removed from the ends of the bent cross tube.

c. Cut equal amounts off of each side.

7) Have one or 2 other people hold the cross tube and tube stubs together in desired
location for tacking. Once satisfied with cross bar fitment and location, fully weld
into place along with the rest of the kit installed up to this point.

LIMIT STRAPS / TABS
**Limit straps help prevent damage to expensive shocks and suspension components
caused by over extension. They are highly recommended for use in any long travel off
road suspensions system.**

8) The rear frame pad provided in this kit has a built in tab to be used as a limit strap
attachment point on the frame side.

9) For the axle side, a LCA bolt or shock bolt can be used to attach the other end of the
limit strap. However, if no satisfactory bolt / bolt hole exists, the flat tab provided in
the kit can be welded on where desired.

a. With limit strap attachment points located, set vehicle suspension at full

droop and subtract about 1” – 1.5” to determine limit strap length. As a
general rule of thumb, limit straps tend to stretch ½” for every 12” of
length so plan accordingly as they will stretch slightly over time.