Synergy 5022-02 User Manual

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

5022-02 JEEP JK REAR LOWER CONTROL ARM GUSSETS

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.

 This is a weld on gusset kit and should be installed by an experienced welder.
 We recommend installing one side at a time.
 **Note** Gas tank removal will be required if 502202-03 Inner gusset plate is desired to be installed on

the passenger side. Steps 9-21 will cover gas tank removal.

PARTS LIST:

 PART NUMBER – PART DECRIPTION

 (2) 502202-01 Rear Lower Control Arm Outer Gusset Plate
 (2) 502202-02 Rear Upper Control Arm Gusset Plate
 (2) 502202-03 Rear Lower Control Arm Inner Gusset Plate

Parts / Tools Needed to complete installation:

 Basic simple hand tools.
 4-1/2” angle grinder with sanding disc, or 3” air sander with sanding disc to prep surfaces for welding
 Welder. Mig is preferred, but stick or Tig are acceptable as well.

INSTALLATION:

1) Installation can be done with the vehicle on the ground and control arms in place, however we advise to

remove control arms as to not melt suspension joint bushings during welding.

2) Start on the driver’s side. Begin by test fitting gusset plates onto the vehicle and marking which areas

need to be prepped for welding. The 502202-01 RLCA Outer Gusset Plate should butt up to the rear
body mount as shown in image 2.1 and 2.2 below.

IMG 2.1 502202-01 RLCA outer gusset, butted up to body mount.

IMG. 2.2 Placement of 502202-01 RLCA outer gusset

3) Next, test fit 502202-02 Rear Upper Control Arm Gusset. Again, bracket should butt up to rear of body

mount as shown in IMG 3.1 and 3.2 below.

IMG 3.1 Upper control arm gusset placement.

IMG 3.2 Reference for Upper control arm gusset placement.

4) Tack 502202-01 outer gusset into place and fully weld the seam highlighted in red in image 4.1 below as

it will be difficult to weld once all remaining plates are in place. Do not weld inner side of bracket at
this time, only outer seams as shown.

5) Tack 502202-02 rear upper control arm gusset into place. Fully weld once desired fitment is achieved.