Synergy 8233 User Manual

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

INSTALLATION INSTRUCTIONS

PPM-8233 XJ TRACK BAR BRACKET

Version 3.0
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.

 Loosely bolt all hardware in until all bolts have been started, then torque to spec.
 This kit requires the use of 4” bump stop spacers to prevent track bar interference at full compression

travel.

 This kit also mandates the use of PPM-3425 Pitman Arm (3.75” drop)

PARTS LIST:

 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

TORQUE SPECS:

 1/2-13 UNC : 80 ft/lbs
 9/16-12 UNC : 110 ft/lbs

1) Install drop pitman arm if there hasn’t been one installed already. Follow factory service manual for

pitman arm removal / replacement.

2) Remove the stock trackbar and track bar bracket on the chassis. The track bar bracket attaches to the

chassis via 2 outer 18mm bolts near the coil, and 2 18mm bolts on the underside of the chassis near the
motor mount. See attached picture. Remove the stock bracket and install the PPM-8233-01 bracket
using the same hardware as shown below.

3) Before installing the PPM-8233-03 trackbar itself, the trackbar mount on the axle needs to be modified.

Begin by drilling out the trackbar bolt hole to 9/16”

After the hole has been drilled out to 9/16”, clean off the face of the track bar mount so the PPM-8233-04

track bar gusset can be welded in place. Align the gusset with the 9/16” bolt provided in the kit and tack

into place. Remove bolt and full weld gusset on, then repaint mount as desired.

Track bar gusset fully welded.

4) The PPM-8233-03 track bar can now be fully installed.

5) Last of the kit to install is the PPM-8233-02 track bar brace. Install using the 4 ½” x 1.5” long bolts and

top lock nuts provided in the kit. Install all hardware loosely until all bolts have been started. The brace
attaches to the track bar bracket as pictured below. Use a washer under both the bolt heads and under
the top lock nuts.

The other end of the trackbar brace attaches to the opposite side of the chassis using the two existing holes in

the chassis and attaches uses the same hardware as shown below.

6) At this time, install 8057-40 bump stop spacers. Follow instructions included with the 8057 kit for

details. This is also a good time to cycle shocks to make sure they are not acting as the bump stop.

7) Reinstall coils, shocks, and tires. Set caster to approximately 7 degrees at ride height. Torque all bolts

to specified settings on pg 1. Align front end.

8) Installation is Complete.