SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
5231 YJ FRONT 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. Fully read through instructions prior to beginning
installation.
• 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-5232; YJ rear cage kit. Also, PPM-5233 YJ Side
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 or soft top.
2) Remove the roll cage padding / covers and the rear upper seat belt mounting bolts. It
is also a good idea to remove the rear seat to prevent damage from welding and ease
installation.
3) Install the PPM-5232 YJ Rear Cage kit per the instructions included with the rear
cage kit.
4) Begin by removing the windshield supports on the driver side. Remove the T-50 bolt
on the B-pillar and the 2 T-40 bolts at the windshield. See pics below.
5) Next, remove the inner T-40 bolt on the lower windshield bracket as well.
6) Next, clean up areas that will be welded. Clean up the area around the bung for the
windshield support tubes. Also, clean up the surface where the top supports will be
installed. See pics below.
7) Begin installation of the new cage by first tacking the 523108 A-pillar Sleeves into
the 523101 A-pillar Floor Tubes. Push the sleeves halfway into the bent side of the
floor tubes so there is 3” of sleeve sticking out of the tube.
8) With sleeve tacked in place, A-pillar fitment can begin. Note that the bottom of the
523101 are cut at an angle and are L&R specific; be sure to install the correct one on
the drivers side.
a. Next, fit the 523102 A-pillar Top tube over the sleeve.
b. Place the cage base plate in the approximate area where the A-pillar
strikes the floor. See pic 8.1b & 8.2b
c. Fit the A-pillar assembly into the Jeep. The notch on the 523102 A-pillar
top tube should just cover the bung for the windshield support tubes. See
pic 8.1c
Picture 8.1b
Picture 8.2b
Picture 8.1c
9) A few key notes to aide in installation:
a. Place a ¼” thick spacer between the dash and the A-pillar floor tube to
properly space the roll cage from the dash. See pic 9.1a
b. Dbl check that A-pillar is perpendicular with the ground / jeep. See pic
9.1a
c. Level the A-pillar top tube to the tub rail. See pic 9.1c
d. Center A-pillar floor tube on cage base plate before tacking into place.
Drawing a 1.75” diameter circle on the center of the plate will make this
easier to fit quickly.
Picture 9.1a
Picture 9.1c
10) Once fitted, place a single tack on each end of the A-pillar to hold it in place. Do
not fully weld anything until all cage pieces have been fitted. Repeat steps 1
through 10 on the passenger side.
11) With both A-pillars tacked in place, fit the 523103 Dash bar in place.
a. Space dash bar up approximately ½” from top of dash. The tube should
intersect the splice in the A-pillars.
b. Level dash bar to top of dash or body of the Jeep. Take a step back and
make sure it looks correct. The dash will not always be perfectly level to
the rest of the Jeep. See Pic 11.1b
c. It will be helpful to use a ratchet strap around the A-pillars to clamp this
tube in place. DO NOT tack weld the dash bar until you fully weld the Apillar splice.
Picture 11.1b
12) Next, fit the 523104 Top A-Pillar Cross Bar in place in addition to the 523105 Top
Spreader Tubes.
a. The bend in the spreader tubes goes towards the front of the Jeep.
b. The 523104 Top A-pillar cross tube is notched at a slight angle to match
the A-pillar angle. Be sure to orient this correctly.
c. Use a pair of ratchet straps or some clamps as shown to square the cross
tube and position it in the proper place for the spreader tubes to fit
correctly. See pic 12.1c
d. The top spreader tubes spacing is up to the installer, however to match the
rear cage kit, they should be spaced approximately 10” apart on center.
See pic 12.1d
Picture 12.1c
Picture 12.1d
13) Mount the A-pillar windshield brackets to the windshield using the stock bolts.
Position the bracket so the bottom and top edges touch the A-pillar. Do not tack at
this time.
14) At this point dbl check that all tubes are aligned, and square or level. Tack weld all
of the joints in this order:
a. Lower A-pillar to floor plate
b. A-pillar splice over dash
c. Windshield cross tube to A-pillar
d. Spreader tubes to windshield and B-pillar tubes
e. Windshield brackets to A-pillars
f. Again, DO NOT tack weld dash bar in place until you completely weld the
A-pillar splice.
15) Drill the cage base plate holes and bolt cage to floor.
16) Weld the A-pillar splice completely, then tack the dash bar in place, again level the
tube to the vehicle.
17) Weld the rest of the joints of the cage and weld the windshield bracket to the Apillar.
18) Position the grab handles as shown below and weld into place.
19) At this point, cage installation is complete. Paint cage desired color to prevent
rusting. It is strongly recommended to install PPM-5205 Cage Tie in Kit to fully
reinforce the cage. If doing so, follow the instructions included in that kit for added
strength and safety.
Complete install including PPM-5232 YJ Rear Cage kit and PPM-5233 YJ Side Cage Kit
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