Synergy 8025 User Manual

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

8021 / 8041 JEEP JK SYNERGY STAGE 1 SUSPENSION SYSTEM

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.

• The installation of this suspension kit requires drilling a 3/8” hole on the front
axle coil buckets.

• Installation requires trimming of the rear track bar bracket and shock brackets with
either a grinder with a cut off wheel or sawz-all.

• You will need basic hand tools, a drill with 3/8” drill bit; a grinder with cut off wheel or
sawz-all, floor jack or automobile lift, and two sturdy jack stands to complete this
installation.

• A list of additional components that can be added to this kit are available on our
website. These components can be purchased and installed at a later date. Each
component has instructions for installation.

• For Non-Rubicon models, we recommend installation of 8077 JK Front
Sway Bar Quick Disconnect Kit for removal of the front sway bar links to increase
suspension articulation while off road.

• The longer rear sway bar links may be close to or rub the inside of the rear tires.
Wheels will less back spacing (4.5” max) or wheel spacers can be used.

• We recommend that you upgrade to conventional double cardon CV style drive shafts
during or soon after the suspension installation. The large diameter front drive shaft may
rub on the automatic transmission pan and the CV boots will tear prematurely due to the
increased operating angle caused by the suspension lift, especially 2 door rear drive shafts
and 2 or 4 door front drive shafts.

1. Unpack the suspension components from boxes; verify that all parts have arrived,
intact and in good condition.

Synergy Stage 1 Parts List

8004 - JK 9/16" Control Arm Cam Bolt Kit
8063XX - JK Front Lift Springs
8064XX - JK Rear Lift Springs
80XX - JK Front Bump Stop Spacer Kit
80XX - JK Rear Bump Stop Spacer Kit
8061 - JK Front Track Bar
8056 - JK Rear Track Bar Bracket
8083 - JK Front Brake Line Relocation Kit
8084 - JK Rear Brake Line Relocation Kit
8060 - JK Rear Sway Bar Links

2. Read all the following steps before beginning installation. If you do not have the
proper tools or ability to install the components properly do not attempt installation.
Find a creditable, local shop to do the installation work.

FRONT SUSPENSION

3. REMOVE STOCK PARTS

• Remove the front track bar. It is easiest to do this when the suspension is at the ride

height position.

• Remove the automatic transmission skid plate if equipped to prevent damage to the

front drive shaft when the suspension is drooped out.

• Remove the rear sway bar links, these will be reinstalled on the front sway bar.

• Use a floor jack under the center of front axle to lift the tires off the ground. Place jack

stands under each frame rail just behind the lower control arm mounts to support the
weight of the Jeep. Raise or lower the floor jack under the front axle to remove and
install suspension components. The jack should stay under the axle the entire time the
front suspension is being installed.

• Now remove these suspension components and retain the hardware in this order:

• Front Wheel/Tires

• Loosen the upper control arm bolts and lower control arm frame mount bolts

• Sway bar links

• Shocks

• Remove the brake line frame bracket bolts, but do not open the hydraulics

• Lower the axle and remove the springs, make sure the wheel speed sensors wires
are not overextended, loosen any retaining clips if needed to allow enough slack.

4. BRAKE EXTENTIONS

● Find the correct front brake line brackets, the front brackets are the shorter
ones, and there is a left and a right. Install the new extension bracket to the frame
with the stock bolt.

● Bolt the brake line to the extension bracket using the new supplied hardware.
You will need to straighten the brake hard line with your hands to give enough
slack for the brake line to reach the extension bracket.

5. FRONT LOWER CONTROL ARM CAM BOLTS

* Cam bolts are necessary if you choose to retain the stock lower control arms. If you do
not want to perform the following procedure you can purchase adjustable lower control
arms. 8051 Synergy Adjustable Front Lower Control Arms

• Remove the lower control arm bolts at the axle housing. Let the control arms drop out

of the control arm mount.

• Remove the cam positioning tabs from the LCA mounts. You can purchase 8004-01 JK

Cam Bolt Knockout Tool or if you have the proper tools you can cut the tabs out.

• You will notice that the bolt hole in the LCA mount is square. There are partially

punched metal tabs at the front and back of the square hole; these tabs need to be
punched out to make the LCA mount slotted. Since you need to increase castor, only the
tabs that are toward the rear of the vehicle need to be punched out. The easiest way to
remove the tabs is to cut the top and bottom with a narrow saw blade (Figures
5-1 and 5-2), then bend/break the tabs out with pliers (Figure 5-3). You may need to
clean the burr from the back edge of the hole with a file or carbide burr for the cam
bolt/washer to fit (Figure 5-4). Do this to each side of both front LCA mounts. Total of
four places.

Figure 5-1

Figure 5-2

Figure 5-3