SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
INSTALLATION INSTRUCTIONS
8519 DODGE 1500 / 2500 / 3500 2.5” SHOCK TOWERS
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.
• This bracket is designed to be bolt on with minor trimming of under hood
accessory brackets. A small dremel or die grinder is ideal for this.
• These towers are designed to run a Fox 2.5 x 10” stroke shock with 1.680” width
spacers for 9/16” bolts. Fox misalignment spacer part number: 213-01-131-A
• The installation of this tower will require the suspension to be drooped out. A
pair of quality jack stands and a floor jack will be needed for installation.
• The following installation is on a 2010 4x4 2500 CTD truck. Other models may
vary in under hood components / trimming.
PARTS LIST:
• 2 - PPM-8519 Front Shock Tower
• 2 - HD shock tower bolt plate
• 2 - 9/16-12 UNC x 5.0” long Gr8 bolt
• 2 - 9/16-12 UNC stover nut
• 4 - 9/16” Gr8 flat washer
• 6 - 7/16-14 UNC x 1.50” long Gr8 bolt
• 6 - 7/16-14 UNC Stover nut
• 12 – 7/16” Gr8 flat washer
INSTRUCTIONS:
1) Begin by removing the track bar attachment point at one side. (Frame side, or
axle side. It is up to the installer)
o Doing this will allow the suspension to fully droop out without binding.
o This is also easiest to do while the vehicle is sitting on the ground, under
its own weight.
2) Once the track bar is disconnected, safely position the vehicle on jack stands to
allow the suspension to fully droop out. Be sure you can support the axle with a
jack or additional jack stands to keep it off the ground.
3) With the suspension drooped out and vehicle safely supported. Remove the
plastic inner fender wells (if equipped). Next, remove the shock absorbers, upper
shock mounts, coil springs, sway bar links and disconnect the brake line bracket
from the control arm mounts on the axle (Image 3.3 below)
o **Note** If stock control arms are being used, it is helpful to loosen the
control arm bolts so the stock control arms will fully droop.
Img 3.1 – Exploded view of stock upper shock mount.
Img 3.2 - Detail view of lower shock bolt.
Img. 3.3 - Remove bolt 2 at the frame side in the image above.
**Note** On older trucks, there is a tie rod end style joint on the track bar at the frame
side. This will need to be disconnected.
Image 3.4 - Stock brake line bracket bolt to be removed.
4) Once the necessary stock suspension components are removed, begin fitment of
the 8519 shock towers.
5) Mock the tower into place and take note of what needs to be trimmed.
6) **NOTE** we will be installing the shock tower and shock as a unit from the top
of the vehicle so keep this in mind when trimming for clearance.
7) On newer trucks with plastic inner fender wells, the battery tray will need some
slight trimming for the towers to be positioned correctly. Take note of where
contact is made and trim off the small support ridge which prohibits the tower
from being installed.
8) As seen below, the tower should sit cleanly in the first slot of the battery tray.
o These images are on the driver’s side. The passenger side will require
similar trimming.
9) On older trucks, with sheet metal fender wells, trim as needed to be able to fit the
tower in place. Be careful not to cut or damage any components mounted to the
steel fender wells.
10) Once trimmed for shock tower clearance, remove the batteries, intake and battery
trays from the vehicles (on plastic inner fender trucks)
11) On truck with steel inner fenders, trim as needed to allow for shock tower / shock
combo to be positioned into the coil bucket from above. Intake and battery
removal will make it easier to trim in these areas.
12) Next, with the tower off the vehicle, install the shock into the tower using the
9/16-12 x 5.0” long bolt provided in the kit.
o Use a washer under both the head of the bolt and under the stover nut.
o Be sure the bolt is installed from the outside with the nut on the engine
side when the tower is installed in the truck.
o Lastly, we recommend having the hose pointing forwards on the tower,
but again this is up to the installer.
13) Install the tower into the vehicle. Be sure to utilize the HD bolt plate included in
the kit with the 7/16-14 UNC bolts installed from the bottom. Use a washer under
both the bolt head and under the stover nut as shown. The nuts should be on the
top side as pictured below.
14) Torque the 7/16” bolts to 50 ft-lbs.
15) Install the coil spring with the coil spring isolator on top. Just how it was
removed.
16) Reinstall the stock lower shock bolt and torque to 100 ft-lbs.
17) Torque the upper shock bolt to 120 ft-lbs.
18) Reinstall the battery trays, batteries and intake in the reverse order of removal.
Take note, reinstallation of the battery trays can be tricky with the towers in place,
but it is doable. If additional trimming is necessary, trim as needed for
reinstallation.
19) Next trim the plastic inner fender wells to clear the towers, resi and hose. In this
installation, we used PPM-8542-02-01 front reservoir mounts to secure the
reservoirs to the coil buckets.
20) Reconnect sway bar links and torque accordingly. (Stock = 35 ft-lbs at axle end)
21) Reconnect brake line bracket bolt removed in step 3.
22) Reinstall tires and lower vehicle to ground.
23) Re-torque stock control arm bolts once the vehicle is on the ground and sitting
under its own weight.
o Control arm torque specs:
1) 14mm (9/16” bolts) – 125-140 ft-lbs.
2) 16mm (5/8” bolts) – 145-160 ft-lbs.
3) 18mm (3/4” bolts) – 200 ft-lbs.
24) Lastly, once vehicle is on the ground, reconnect the track bar and torque to
specification. 125-150 ft-lbs depending on bolt size.
25) Installation is complete.
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