Synergy 8009-30 User Manual

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

PPM-8009 JK DANA 44 HD FRONT AXLE GUSSET
KIT

Version 1.0

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.

• Please read these instructions carefully before you start, do not attempt if you do

not have the tools or skills required.

• This kit only works on a factory JK front Dana 44 axle housing

• This kit requires you to cut off all the factory axle brackets, careful cutting,

measuring and welding is involved, do not attempt if you do not have the skills to
properly perform this operation

• You will need a welder, cutting torch or plasma cutter, grinder, tape measure and

some sort of level or angle finder.

• For best results when welding to the cast diff housing, we recommend TIG

welding with stainless 312 rod or similar rod that is meant for cast iron welding to
mild steel. MIG and stick welding is also possible with the right rod, pre and post
heat.

1. Unpack all of the components and verify all the parts are there and are in good
condition. These are the parts that are included

• 8009-00 Short and long outer axle sleeves

• 8009-01 Track bar bracket and sway bar tab

• 8009-02 Lower control arm brackets (pair LH & RH)

• 8009-03 Lower shock mount brackets (pair LH & RH)

Optional parts

• 8009-07 Inner C gussets, 2 sets (4 pcs total)

• 8009-09 Axle truss

• 8009-10 Hydro assist ram bracket

2. Remove axle housing from the vehicle, you do not have to remove the gears &
locker, axle shafts or knuckles.

3. Using a plasma cutter or oxy-acetylene torch, cut off all of the suspension brackets
from the axle tubes, refer to the following steps for specific instructions.

4. Cut off the sway bar tabs and coil spring mounts on both sides. The coil spring
mounts will be re-used so try to just cut along the top edge of the weld bead on the

side of the coil mount. This will compensate for the 1/4” thick shell that will go
under it. Tag the left and right so you can put them back on the side they were
removed from. The sway bar tabs will not be reused.

5. Cut off the track bar bracket, this will not be reused so try to cut most of the weld
bead off the tube so you will have less to grind.

6. Cut off the lower control arm brackets and shock mounts. These will not be
reused so try to cut most of the weld bead off the tube so you will have less to grind
off.

7. Cut off the upper control arm bracket. The upper control arm bracket will be re­used so try to just cut along the top edge of the weld bead on the side of the upper
control arm bracket. This will compensate for the 1/4” thick shell that will go under
it.

8. Grind all the of weld smooth from the axle tube. It should look something like this
when you’re done, these are the parts you will need to reuse

9. We recommend that you weld the axle tubes to the cast center section. Tig welding
with stainless 312 or similar dissimilar metal welding rod works best. You can also
mig or stick weld with pre and post heat.

10. Prepare the outer tube shells by deburring the inside of the laser cut edge, make sure
there is no slag from the laser cut edge on the inside of the tube and the inside of the
holes. Grind a chamfer on the outside radial edges of both ends of the tube shells for
a V groove to weld the outer tube shell to the cast center and inner C. Grind a
chamfer for clearance of weld bead at the center section in step 9.

11. Position the outer tube shells to the axle tube. The holes should be oriented at the top
and bottom with the seam at the front and back. Do one at a time by clamping the
tube shell to the tube and tack welding it to the axle tube

Make sure the seam is even on the front and back