Synergy 8259-02 User Manual

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

8259-02 XJ SWAY BAR LINK KIT – FRAME SIDE DISCONNECT

BRACKETS

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.

 NOTE – This kit is designed to be used in conjunction with 8259 XJ Front Sway Bar Link Kit.

PARTS LIST:

 8259–02 XJ SWAY BAR LINK FRAME MOUNT BRACKETS

 (2) 8259-02 Front Sway Bar Link Frame Disconnect Bracket
 (3) 7/16-14 x 1.0” long hex head bolt
 (1) 7/16-14 x 1.5” long hex head bolt
 (8) 7/16” flat washer
 (4) 7/16-14 nylock nut
 (2) 807701 Sway Bar Disconnect Stud
 (2) ½” Gr8 Flat Washer
 (2) ½-20 UNF Stover Nut

Parts / Tools Needed to complete installation:

 Basic simple hand tools.
 Anti-seize, chassis grease
 4-1/2” angle grinder or 3” air sander for slight material removal.
 Quality drill and 7/16” metal cutting drill bit.

INSTALLATION:

1) Installation can be done with the vehicle sitting on the ground, under its own weight.

2) First, prepare the disconnect brackets for installation. Install the disconnect pins onto the bracket as

shown. Use a washer under the nut and orient the stud as shown on the bracket below.

3) We will begin on the driver side. There are 2 factory holes which we will use for installation on the

driver’s side. Located in the fender well, nearly directly underneath the factory air box. The holes can
be seen in image 2.1 and 2.2 below.

Image 2.1

Image 2.2

4) After locating the 2 holes to be used for installation, open them up slightly with a 7/16” drill bit. Be

careful not to drill into any electrical components under the hood or into the air box.

5) Once holes have been clearanced, install the bracket as shown. Use 2 of the 7/16-14 x 1” long bolts and

install with a washer under both the bolt head and nut as shown. Torque bolts to 35 ft-lbs. Installation
is complete on the driver’s side.

 Test that disconnect operates smoothly and lynch pin can easily be removed / installed.
 Note, a small amount of grease on the stud is helpful for the first few uses.