Synergy 8091 User Manual

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

PPM-8091 JK FRONT TRACK BAR RELOCATION
BRACKET, RIGHT HAND DRIVE

Version 2

GENERAL NOTES:

• On Rubicon models the installation of this bracket requires some minor grinding

on the diff housing, no other cutting or drilling is required.

• This bracket should be used with the PPM-8001 drag link flip kit.

• You must use a minimum of 3” of front bump stop extension, PPM-8057 (3”) and

PPM-8075 (4”) to prevent the track bar and bracket from hitting the bottom of the
frame at full jounce travel.

• If you have a Rubicon model or front Dana 44 and and ARB diff cover, you will

need to trim this track bar relocation bracket to fit.

1. Remove the factory front track bar from the axle bracket and loosen the track bar
from the frame bracket to allow the track bar to rotate out of the way. Secure the
track bar up and out of the way with a bungee cord or something similar. Also
remove the steering stabilizer.

2. Remove the factory anti-sway bar links from the axle brackets, or remove completely
if using new anti-sway bar links.

3. If you have and ARB diff cover and a Rubicon model with a Dana 44, trim 7/16
(10mm) front the end of the track bar relocation bracket.

4. Position the new PPM-8091 track bar bracket over the stock track bar bracket as
shown below. Secure the bracket to the sway bar tab using the supplied 1/2 x 3” bolt
and spacer. There are 3 cylindrical spacers included with this kit, use one of the
longer 1.5” (38mm) ones for this step. Use a washer under the head of the bolt and
under the toplock nut. Do not tighten any of the track bar bracket hardware until all
of the hardware is installed.

5. Insert the shortest of the 3 spacers where the stock track bar bushing was. Install the
9/16 x 3” bolt in the track bar relocation bracket through the stock track bar mounting
hole. Use a flat washer under the bolt head and under the lock nut.

6. If you have a Dana 30, use the supplied shim between the housing and the track bar
relocation bracket. Install the u-bolt over the diff housing and through the track bar
relocation bracket, use a flat washer and nylock nut to secure the u-bolt.

7. If you have a Rubicon with a Dana 44, you will have to grind the bottom web slightly
to clear the u-bolt. Do not use the shim. Install the u-bolt over the axle housing and
through the track bar relocation bracket, use a flat washer and nylock nut to secure the
u-bolt.

8. Once all the hardware is installed in the track bar relocation bracket you can begin to
torque all the hardware. Torque the 9/16 bolt to 150 ft-lbs (200 N-m), the ½” bolt to
90 ft-lbs (120 N-m), and the 3/8” U-bolt nuts to 30 ft-lbs (40 N-m).

9. The anti-sway bar relocation bracket works in conjunction with the track bar
relocation bracket to raise the anti-sway bar mounts by 2”. This is required when
using the Poly Performance sway bar disconnect kit and/or using the Poly
Performance Sway bar link kit. If you are relocating the anti-sway bar link mounts
refer to step 9 & 10. If you want to keep the anti-sway bar links in the stock location,
skip step 9&10 and refer to step 11.

10. Attach the passenger side sway bar link to the upper hole in the track bar relocation
bracket using the stock bolt and nut.

11. Install the driver side anti-sway bar relocation bracket using a 1.5” (38 mm) spacer
and ½” x 3” bolt and top-lock nut; use a washer under the bolt-head and nut. Tighten
the ½” bolt to 90 ft-lbs (120 N-m), and the sway bar link bolts to 90 ft-lbs (120 N-m).

12. If you are not using the anti-sway bar relocation brackets and want to mount the sway
bar links in the factory location, install the passenger side anti sway bar link between
the track bar bracket and factory sway bar tab as shown below. Attach the driver side
anti-sway bar link in the factory location.

13. Install the steering stabilizer to the track bar relocation bracket. Attach the body end
of the steering stabilizer to the track bar relocation bracket using the factory nut and
bolt.

14. Loosen the clamping bolt on the tie rod steering stabilizer bracket and rotate it to the
top of the tie rod, fully compress the steering stabilizer and turn the wheels all the
way to the left. Attach the steering stabilizer to the tie rod bracket.

15. Rotate the tie rod clamp forward enough that the steering stabilizer clears the diff
cover. Turn the tires all the way to both sides to verify clearance and that the steering
stabilizer does not limit the steering angle. When the tie rod clamp is positioned
correctly, tighten the clamping bolt.

16. Reattach the track bar using the factory nut and bolt, it helps to have someone turn the
steering wheel to align the track bar to the hole in the bracket. Torque the factory
track bar bolts to 125 ft-lbs (170 N-m). Remember to tighten the track bar frame
mount bolt if you loosened it earlier.

17. You will probably have to re-center the steering wheel. Adjust the draglink to center
the steering wheel. If the steering wheel is not centered the ESP light will come on,
so make sure you adjust the draglink so the steering wheel is perfectly centered. This
can be accomplished by test driving and making the necessary adjustments. When
driving in a straight line take note of which way the steering wheel need to turn to be
centered. If the steering wheel needs to turn right to be centered, shorten the draglink.
If the steering wheel needs to turn left to be centered, lengthen the draglink.