Synergy 8009-40 User Manual

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SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
PPM-8009-40
Poly Performance Jeep JK Front Dana 44 Extreme Re-Tube
Installation instructions for re-assembly of axle after Synergy Suspension re-tube kit installation.
1. Re-install carrier/ring gear.
Use a differential housing spreader to spread the housing for carrier/ring
gear installation. Do not spread housing over 0.020”
Install differential case into the housing with differential bearing cups and
shims in their original locations.
Install bearing caps (2) in their original locations and coil anti-rotation
bracket (1).
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Loosely install differential bearing cap bolts.
Remove housing spreader
Tighten bearing cap (1) bolts in a criss-cross pattern to 108 N·m (80 ft.-
lbs).
Install Tru-Lok coil connector (2) to the coil harness (1).
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Install Tru-Lok coil connector (1) and install bolt.
Install Tru-Lok harness to the coil connector (1) and indicator switch (2).
Install differential cover with silicon sealant. Tighten bolts to 30 ft.-lbs.
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2. Install knuckles, axle shafts and brakes.
Install the knuckle to the ball joint studs.
Install the lower ball joint nut and cotton pin. Tighten to 75 ft-lbs.
Install the upper ball joint nut and cotter pin. Tighten to 70 ft.-lbs.
Install the wheel speed sensor (1) through the hole in the brake shield (2).
Install axle shaft (2) with hub bearing (1) through steering knuckle and
into differential side gears.
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Install three hub bearing bolts (1) through steering knuckle (2) and tighten
to 102 N·m (75 ft. lbs.).
Install hub nut (1) on axle shaft (2) and tighten to 136 N·m (100 ft. lbs.).
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Install the wheel speed sensor (1) in the hub/bearing and tighten the bolt
(2) to 4-6 N·m (34-50 in. lbs.).
Install disc brake rotor.
Install the caliper onto the knuckle with the two bolts (1). Tighten to 120
ft. lbs.
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The following table can be used for reference for re-installing the
suspension components back onto the axle. Torque all control arm and track bar hardware with the vehicle on the ground under full weight. *** Be sure to add gear oil to differential before driving ***
Front Suspension DESCRIPTION N·m Ft. Lbs In. Lbs. Shock Absorber Upper Nut Shock Absorber Lower Nut Suspension Arm Lower Axle Bracket Nut Suspension Arm Lower Fram Bracket Nut Suspensions Arm Upper Axle Bracket Nut/Bolt Suspension Arm Upper Frame Bracket Bolt Stabilizer Bar Retainer Bolts Stabilizer Bar Link Upper Nut Stabilizer Bar Link Lower Bolt Track Bar Frame Bracket Nut Track Bar Axle Bracket Bolt Hub/Bearing Bolts 102 75 ­Hub/Bearing Axle Nut 136 100 ­Jounce Cup Bolt 42 31 ­Drag link to Knuckle (Right Side) Drag link to Knuckle 74 55 ­Axle Shaft Nut 136 100 ­Wheel Speed Sensor 4-6 - 34-50
27 20 -
76 56 -
169 125 -
169 125 -
102 75 -
102 75 -
61 45 -
102 75 -
102 75 -
169 125 -
169 125 -
74 55 -
Synergy Suspension 870 Industrial Way Suite B San Luis Obispo, CA 93401 Ph. (805)-242-0397 www.synergymfg.com
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