Synergy 5224-A User Manual

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

PPM-5224-A JK 4 DOOR REAR CAGE KIT

Version 1.1

GENERAL NOTES:

• These instructions are also available on our website; www.polyperformance.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-A; 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 and the
entire soft top and bow assembly.

2. Remove the sound bar and unzip the rear roll bar padding.

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

4. Unzip the C-pillar cross bar padding and remove the interior lamp. Position the C­pillar spreader bar bracket over the C-pillar cross bar. The triangle points forward
and the holes should line up with the holes in C-pillar cross bar. Cut holes in the
padding cover where the tubes will go through, you will need to notch the padding on
the bottom of the C-pillar cross bar. Mark the edges of the bracket on the cross bar.
Remove the paint for welding.

5. Position the C to B pillar spreader bars, the ends of the tubes should fit into the cutouts
in the C and B pillar spreader bar brackets. The bends in tubes should be at the rear
of the tubes.

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

6. Slide the padding forward and weld both ends of the spreader bars, weld the top, front
and back of the C pillar bracket to the C pillar cross bar, also weld the bottom edge
around the tubes, ends and middle of the bracket.

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

7. Fold the rear seats forward, remove the lower seat and seat belt mounting nut, position
the C-pillar foot plate over the studs and replace the nuts.

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

8. Drill the rear foot plate holes through the floor with a 3/8” drill bit. Use caution when
drilling through on the driver side, the fuel filler hoses are underneath these bolt
holes. Insert 3/8 x 1” bolts and flange nuts with a washer under the bolt head.
Tighten the 3/8” bolts and the seat and seat belt nuts evenly.

9. Position the C-pillar upright tubes between the foot plate and the bend in the C-pillar
beneath the C-pillar cross bar. The top of the tube is about 4” in front of the seat belt
mounting bung. Clean off the paint on the factory roll bar where you will weld the
tube. The bottom of the tube should be centered on the foot plate. Make sure the rear
seats will fold back all the way and lock without hitting these tubes.

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

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

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

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

10. Cut a hole in the roll bar padding cover where the C-pillar upright tube goes through.
Position the tube through the hole in the padding and tack weld into place.

11. Included in this kit is also a rear passenger harness bar. If desired, install at this time.
It should be positioned just about an inch below the top of the rear seat as shown to
ensure proper harness mounting points. See image 11.1 below. Be sure tube is level
with the vehicle and that the seats clear when in the fully up position. Tack weld into
position once satisfied.

Img. 11.1

12. Fully weld C-pillars and harness bar in vehicle.

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

13. Clean and paint the new tubes and where they are welded to the factory roll cage

14. Trim the C pillar padding to fit around the new tubes and zip up the padding

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

15. Notch the factory sound bar to fit around the spreader bars

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

16. Installation is complete.