SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
8569-03 DODGE FRONT AAM 9-1/4” TRUSS KIT
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.
Please read these instructions carefully before beginning, do not attempt to install if you do not have the
tools or skills required.
**Note** installation of truss plates involved optional welding to cast housing center section. This
should be performed by an experienced welder using methods described in these instructions.
For best results when welding to the cast diff housing, we recommend Tig welding with stainless
312 rod or similar rod that’s is meant for cast iron welding to mild steel. MIG and stick welding
is possible with the right rod used with pre and post heat.
This truss tube is compatible with all axle housings from 2003-2012
This truss kit is designed to be used in conjunction with Synergy parts: 8561 / 8569 Dodge AAM Front
Axle C-gusset kit
PARTS LIST:
(1) 856903-01 Truss Plate, Long Side
(1) 856903-02 Truss Plate, Short Side
(1) 856903-03 Lower Truss Tube
Parts / Tools Needed to complete installation:
Basic simple hand tools.
4-1/2” angle grinder with cut off wheel and abrasive attachments to remove paint from inner C’s
Some form of welder. Tig is preferred for welding to cast center section, but Mig or stick can be used
with proper pre-heat and post-heating methods.
APPROXIMATE INSTALL TIME: 4-6 HOURS
INSTALLATION:
1) Installation can be done with axle still installed in vehicle, however welding becomes more difficult. In
these instructions, the axle has been removed from vehicle. Follow service manual for axle removal if
desired.
2) After installing C-gussets. (See 8561 / 8569 instructions for C-gusset installation) Begin by fitting axle
truss tube as shown below. Truss tube should be centered front to back on bottom of C-gussets and fit
behind front lip of cast center section.
3) Take note of fitment around cast center section of housing in circled area above. Tube should fit down
so that it can be welded both to the bottom of the C-gussets and to the center section of housing.
4) Housing ribs may need to be grinded down slightly for a perfect fit.
5) Once satisfied with tube fitment, remove paint / rust from weld surfaces and tack truss tube in place on
C-gussets.
6) Next, fit the long side truss plate (856903-01) as shown. Truss plate will need to be trimmed or last
piece of lower control arm gusset cut off.
7) Truss plate should fit directly under truss tube and align with rib on center section as shown. Note, rib
on casting is not in the same plane as the truss tube, however the entire length of truss plate should fit so
it is weldable.
8) Truss plate may end up being slightly tall to allow for variances in tube and axle fitment. If needed trim
the edge of the truss plate which meets with the truss tube until proper fitment is achieved.
9) Once satisfied with fitment, remove paint and clean all areas to be welded. Tack truss plate in place.
10) Repeat steps 5-8 for the short side plate (856903-02).
11) Fully weld truss plates. Note, weld on front side primarily. Wrap onto back side and add a pass or 2 on
the back of the plates.
12) Weld both front and back of seams which meet up with the casting. We recommend tig welding with
stainless 312 or similar dissimilar welding rod.
13) Allow welds to cool. Slow cooling is the recommended for cast welds, IE post heat. Once welds are
cooled, paint all areas of exposed metal to prevent corrosion and reassemble.
Installation is Complete
Loading...