Synergy 8080 User Manual

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

INSTALLATION INSTRUCTIONS

PPM-8080 JK R TRACK BAR BRACE

GENERAL NOTES:

 These instructions are also available on our website at www.synergymfg.com Check the website for any

updated instructions and additional photos for reference.

 Bracket is designed to be bolted on but can be welded on as well if desired.

PARTS LIST:

 1 - PPM-8080 JK R TB BRACE
 2 - 7/16”-14 UNC 1” long bolt
 1 - 7/16”-14 UNC countersunk bolt
 3 - 7/16”-14 UNC Stover nut
 5 - 7/16” flat washer
 1 - ½-13 UNC bolt 1” long
 1 - ½-13 UNC Stover nut
 2 - ½” flat washer
 1 - 9/16”-12 UNC bolt 3.25” long
 1 - 9/16”-12 UNC Stover nut
 2 - 9/16” flat washer

INSTRUCTIONS:

1) Begin by removing the rear TB bolt and nut at the frame side (#2 in picture below). This is easiest to

do with the vehicle still sitting on the ground under its own weight.

2) Next, jack up the vehicle and support it using jack stands. Note; suspension does not need to hang

free, the vehicle just needs to be supported to allow removal of the passenger rear tire.

3) Once vehicle is supported with the rear tire removed, fit the PPM-8080 JK rear TB brace onto the

vehicle. Begin by fitting the brace into place and aligning it with the 3.25” long 9/16” bolt provided
in the kit. Slide bolt through and start nut to hold bolt in place. DO NOT TIGHTEN.

4) Start the 2 7/16” bolts and ½” bolt as shown in the pictures below. Do not tighten yet. Simply start

bolts and nuts to align bracket.

5) Once all bolts are started (with the exception of the countersunk bolt which requires drilling) tighten

the 9/16” TB bolt to fully locate bracket. Do not overtighten to the point of bending the stock TB
mount. Simply tighten to the point as to not allow the TB brace to move, this will locate the bracket
to make sure the TB bolt can still be removed easily for serviceability.

 Tighten the other 3 bolts to fully locate TB brace.
 Mark and center punch the hole for the countersunk bolt. (We recommend removal of

the new TB brace prior to drilling to prevent damage to powder coat, but the hole can be
drilled at this time without removing brace.)

6) Remove TB brace and drill 7/16” diameter hole.

7) Deburr hole and reinstall TB brace in the same order and procedure as before.

8) Torque bolts as follows:

 7/16-14 UNC – 55 ft-lbs.
 ½-13 UNC – 80 ft-lbs.

9) Reinstall rear tire and lower vehicle to the ground. Connect TB and new TB bolt and torque to 125 ft-

lbs.