Synergy 8200 User Manual

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

INSTALLATION INSTRUCTIONS

PPM-8200 XJ LONG-ARM SUSPENSION

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.

 Cutting and grinding of stock control arm brackets is required for installation.
 Brackets can be bolted or welded on.
 Loosely bolt all hardware in until all bolts have been started, then torque to spec.
 This kit is designed to be run at a minimum of 4” of lift and requires the use of a 4” bump stop spacer to

prevent track bar interference at full compression travel.

 A Slip Yoke Eliminator kit will likely be needed in the rear for lift heights above 4”

PARTS LIST:

 8230– XJ LONG ARM FRAME BRACKET

 (1) 823001-L
 (1) 823001-R
 (2) 823002 XJ Long Arm UCA nut tab
 (12) 3/8-16 UNC x 1” long hex head bolt
 (12) 3/8-16 UNC Nylock nut
 (24) 3/8” flat washer
 (4) 3/8-16 UNC x ¾” long thread cutting screw
 (4) 9/16-12 UNC x 4” long hex head bolt
 (2) 9/16-12 UNC Stover Nut
 (6) 9/16” flat washer
 (2) 9/16” lock washer

 8231– XJ LONG ARM LOWER CONTROL ARM (PAIR)

 (1) 8231-01-L Left Lower Control Arm, XJ Long arm (Assembled)
 (1) 8231-01-R Right Lower Control Arm, XJ Long Arm (Assembled)

 8232– XJ LONG ARM UPPER CONTROL ARM (PAIR)

 (1) 8232-01-L Left Lower Control Arm, XJ Long arm (Assembled)
 (1) 8232-01-R Right Lower Control Arm, XJ Long Arm (Assembled)

 8233– XJ FRONT TRACK BAR BRACKET AND BRACE KIT

 (1) 823301 XJ Front Track Bar Bracket
 (1) 823302 XJ Front Track Bar Brace
 (4) ½-13 UNC x 1.5” long hex head bolt
 (4) ½-13 UNC Stover nut
 (8) ½” flat washer

 8233-03 – XJ FRONT TRACK BAR

 (1) 8233-03 XJ Front Track Bar (Assembled)
 (1) 823304-01 XJ Track Bar Hole Gusset
 (1) 823304-02 XJ Track Bar Nut Tab

 8057-40 – JEEP JK/LJ/TJ/XJ/ZJ FRONT BUMP STOP SPACER KIT - 4.0" LONG

 (1) 8057-40 4” Front Bump Stop Spacer (Pair)
 (2) 3/8-16 UNC x 4.5” long socket head cap screw
 (2) 3/8-16 UNC Flange Nut

 8240– XJ REAR SPRING HANGER BRACKET (PAIR)

 (1) 8240-01-L Left XJ Rear Spring Hanger Bracket
 (1) 8240-01-R Right XJ Rear Spring Hanger Bracket
 (20) 3/8-16 UNC x 1” long hex head bolt
 (20) 3/8-16 UNC Nylock nut
 (40) 3/8” flat washer
 (2) 9/16-12 UNC x 4.5” long hex head bolt
 (2) 9/16-12 UNC Stover nut
 (2) 9/16” flat washer

 3425 XJ/TJ/LJ/YJ DROP PITMAN ARM (3.75” DROP)

 8254– XJ LONG TRAVEL 1” LIFT SHACKLE

 (2) 825401 XJ Long Travel Lift Shackle (1 pair, assembled)

 8260-01– JEEP XJ 1984-1989 BRAKE LINE KIT (5-7" LIFT)

OR
 8260-02– JEEP XJ 1990-2001 BRAKE LINE KIT (5-7" LIFT)

Parts / Tools Needed to complete installation:

 Basic simple hand tools.
 Drill with 1/4”-3/8” metal cutting drill bit.
 Spot weld Cutter. Part Number: 4096A11 on www.mcmaster.com for example.
 Quality Jack and Jack Stands
 4-1/2” angle grinder with cut off wheel, grinding disc and sanding disc
 Plasma cutter / Oxy Acetylene Torch (Optional)

APPROXIMATE INSTALL TIME: 12-16 HOURS

TORQUE SPECS:

 1/2-13 UNC : 80 ft/lbs
 9/16-12 UNC : 110 ft/lbs
 3/8-24 UNF : 40 ft/lbs

1. Jack up the front of the vehicle by placing the floor jack under the center of the axle, support the vehicle

using jack stands and allow the front axle to hang free (keep the floor jack under the axle for the
duration of the installation). Remove the wheels, upper and lower control arms, trackbar, and coils.
Unbolt the shocks from their lower mounts.

2. Next, cut off the stock lower control arm brackets.

The control arm brackets consist of several layers of sheet metal and can be removed in approximately 4

cuts.

Cut 1 (Outer Edge):

Cut 2 (Back Edge):

Cut 3 (Inside Edge):

Cut4: Cut off any remaining pieces of the bracket so that the bottom of the unibody looks like this. This is also

a good time to grind smooth all edges.

3) Trim upper control arm mounts as shown in picture.

4) Once the stock control arm mounts have been cut / trimmed, installation of the new PPM-8230 control

arm bracket can begin.

5) First, support the transmission and remove the transmission cross-member. Fit up the PPM-8230

control arm bracket by bolting it to the body using the 2 transmission cross-member bolts as shown in
the picture. (Note, some trimming of the uni-body may be required depending on the year of the
vehicle. See 2nd picture below for reference on where to cut.)

Possible trimming of the unibody is required depending on vehicle yr. (Note, cut is made inside of ruler.)