Synergy 5222-A User Manual

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

PPM-5222 JK 2 DOOR REAR CAGE KIT

Version 1.1

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.

• This is a weld in roll cage kit, all welding should be performed by an experienced

welder with proper welding equipment

• Use in conjunction with PPM-5221; JK front cage kit

• 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.

1. Remove the hard top or soft top, if using a soft top, remove the door surrounds.

2. Remove the sound bar, front and rear upper seat belt mounts, rear roll bar padding and
B-pillar padding and trim.

3. Install the PPM-5221 front cage kit per the instructions included with the front cage
kit.

4. Remove the paint on the factory cage around the areas to be welded. Position the C­pillar cross bar and the B to C pillar spreader bars as shown below. The distance
between the outside of the spreader bars and the factory cage should be 9”.

5. Position the C-pillar cross bar gussets as shown below. The lower part of the gusset
goes right inside of the upper seat belt mount and the upper part goes right below the
top spreader bars.

6. Position the B to C pillar side diagonal tubes, the bend end goes to the B-pillar so the
bend is to the inside. The strait end goes on the bottom of the bend in the C-pillar
where the C-pillar spreader bar connects. The bend is to clear the soft top frame.

7. Included in the kit is a front seat harness bar. It is a straight tube that is designed to be
positioned along the B to C side diagonals as pictured below.

8. Position the driver’s seat in a comfortable driving position and install the harness bar
so it acts as a proper harness attachment point. Please follow the Crow diagram
below if unfamiliar with mounting harnesses.

9. A ballpark figure for the harness bar location is approximately 23-1/2” on center with
the upper diagonal junction. See images below.

10. Be sure to check that the harness bar is level with the rest of the Jeep and tack into
position.

11. You can finish weld all of the tubes now. If you want to retain the factory roll bar
padding you will have to cut holes where the tubes attach, position the tubes through
the padding, slide the padding over the tubes and weld.

12. Clean the welds and paint the new tubes.

13. You can retain the factory sound bar by notching the top of it to clear the B to C pillar
spreader bars.

14. Installation Complete.