Synergy 5013 User Manual

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

PPM-5013 JK REAR C/O KIT

Version 3

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 the PPM-5013 JK R C/O kit requires minimal cutting and

grinding and a significant amount of welding. An experienced fabricator/welder
is recommended to properly install this bracket.

• Factory coil mounts remain unchanged with this installation and can still be

utilized. This kit can act as a long travel shock mount to mount longer universal
shocks and bypass the factory shock mounts for increased travel and articulation.

• **NOTE**: The installation of this kit requires rerouting of the factory exhaust

and removal of the factory rear sway bar. It is highly recommended this
installation be paired with the installation of a rear Currie Antirock sway bar
(CUR-9900JKRA)

• This kit is designed around fox 2.0” coil-over shocks. If using King 2.0” coil over

shocks, a 90 deg hose end will be needed at the body to prevent contact with the
5013 cross member.

PARTS LIST:

• 1 PPM-5013 JK rear c/o cross member (Fully welded)

• 2 PPM-501302-01 JK rear upper c/o mount outer gussets

• 2 ½-13 UNC 2.75” long bolts

• 2 ½-13 UNC Stover nuts

• 4 ½” flat washers

INSTALLATION:

1) Begin by removing the rear TB bolt and nut at the frame side (#2 in picture
below). This is easiest to do with the vehicle still sitting on the ground under its
own weight.

2) Next, jack the vehicle up and support it using jack-stands to take the weight of the
vehicle off the suspension.

! Remove the rear wheels, coil springs, shocks, rear sway bar links, and the

sway bar itself.

3) As noted earlier, the factory exhaust will not work in conjunction with this kit.
So, remove the factory muffler and cut the exhaust hangars off the frame as
shown below.

Grind these areas smooth and remove all paint from the inner frame rail between the rear
most body mount and the factory shock mount. Also clean the forward face of the body
mount as the rear cross member will weld to this as well.

4) Before fitting the PPM-5013 cross member, it is recommended to paint all sides that
do not get welded before installation into the vehicle. Note: do not paint edges
marked with red arrows shown below (both sides, front and back).

5) Position the new 5013 cross member and clamp into place as shown. The cross­member flanges locate it against the bottom of the frame and against the rear body
mount as shown. Note: do not weld anything yet, but take notice of any areas of the
frame that may still need cleaning for welding.