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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.
• Install Tru-Lok indicator switch (1) into differential housing (2).
• 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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