Synergy 5222-04 User Manual

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

PPM-5224 JK 4 DOOR REAR CAGE KIT

Version 1.2

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 in harness bar, all welding should be performed by an experienced

welder with proper welding equipment

• This kit works with either a soft top or hard top

• Use extreme care when welding and grinding in the interior of your Jeep, remove

or cover any components you do not want welding spatter or grinding sparks to
damage.

INSTRUCTIONS:

1. Remove the hard top or soft top. If using a soft top, remove the door surrounds and
the entire soft.

2. Remove the roll bar padding, upper seat belt bolt and upper B-pillar trim from both
sides. Use a trim stick or similar trim removal tool to remove the plastic trim piece.

 #2 in the picture below needs to be removed. There are 2 push

pins in location #1 that secure it to the roll bar.

3. Test fit the 5222-04 harness bar as shown below. It should use the soft top hinge
brackets as a guide for proper location.

 Note. If Jeep is not equipped with a soft top, the top of the bar

should be in line with the rectangular cutout in the b-pillar when
looking from the side.

 The harness bar locates in a position where the B-pillar is formed

and not a perfectly round tube. It is also angled up slightly when
observed from the side. Refer to images below.

4. Once B-pillar trim is removed, remove the soft top hinge brackets bolted to the B­pillar to allow for paint removal in preparation for welding.

5. With weld area clean and ready for welding, refit the harness bar and ensure that the
height will allow for proper harness mounting with the front seats in a comfortable
driving position. If unfamiliar with mounting harnesses, follow the Crow Harness
diagram below.

6. Once satisfied with harness bar location, double check that the bar is level with the
rest of the Jeep and tack into position.

7. Double check driving position and harness location prior to fully welding. Once
satisfied, fully weld the harness bar into position.

8. Deburr welds and paint the harness bar the desired color.

9. Reinstall and trim any interior pieces as needed for reinstallation.

10. Installation is complete.