Synergy 5221-A - 2011+ Jeep JK 2/4 Door Front Cage Kit Manuel d'utilisateur

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 PPM-5221-A JK 2 & 4 DOOR THRU DASH FRONT CAGE KIT (2011- Present Models

19. With the A-pillar floor plates and cage tie-ins mocked into position, we will begin fitting the A-pillars behind the dash. 20. We will start

Image 21.1 Image 21.2 Image 21.3 22. Next, remove the dash end caps. A flat nose screw driver or quality trim removal tool works best. Both styl

23. With dash end caps removed, remove the trim piece under the steering column. It is attached with 4 clips on either side of the steering wheel

24. Remove the 4 small bolts shown in the images below on either side of the steering column. (7mm bolt head)

25. Next remove the small bolt under the upper dash tray. Access it by removing the top organizer insert panel. (It simply pulls straight up).

26. Next, remove the center power window switch assembly (or center storage pocket if equipped with manual windows). It is secured with plastic

27. Disconnect the electrical connection by sliding the red lock tab up (see direction of arrow below). Then, like other factory connectors, press

29. Now the upper dash cover can be removed. With all the bolts removed from the previous steps, it is now only being secured to the dash via plas

30. With the upper dash cover removed, remove the four 7mm bolts securing the instrument cluster to the dash. Then disconnect all wiring which is

4. Mark the edges of the bracket and sand the paint off to prep the weld area, reposition the bracket and tack weld it on. 5. Position the A-pil

32. On the underside of the dash, remove the 7mm bolt next to the OBD port. 33. Remove the speaker from the driver’s side. There are 2 out

10mm bolt removal on underside of speaker pod

34. With speakers removed, we can begin trimming the necessary parts behind the dash to snake the A-pillar tube through. Start by cutting down the

35. After cleaning up the edges from this first cut, the second cut will be on the bottom portion of the dash structure. Remove the outer lower bo

36. Next, move back up to the top portion of the behind dash structure. Measure from the firewallattachmentsurfaceback.Markalineat2”back

Img. 36.1 37. Take note that additional notching may be necessary in this final cut area in order for the door to close without contacting the tub

Upper dash template mocked into position on upper dash cover. ***Upper dash cover can be trimmed at a later time. It is not critical to trim at t

They should work as a great starting point, however with any weld it yourself kit, there will be variances due to installer preferences. Careful me

6. Position the A to B pillar spreader bars, the rear of the bars fit in the cut-outs of the B-pillar cross bar bracket, align the front so the

41. Mark the portions of the dash to be trimmed appropriately. Take your time and cleanly trim the dash until the tube will cleanly fall into pla

43. The tube should lock into position by pulling the bottom of it back and towards the outside of the floor plate. Meanwhile, the top of the tube

44. At this time, take note of where the tube contacts the A/C ducting. Some trimming of the ducting will need to take place. Use a marker or pen

45. Clean up edges and trim until tube tucks neatly into place and door can close without contacting the tube. 46. In order to close the door fu

Dash template on passenger side. Note step on lower right corner of template lines up to notch / step on the dash.

47. With dash notched for adequate tube clearance, be sure dash end caps will reinstall. The top attachment point of the end caps will need to

7. Weld the B-pillar cross bar bracket. Weld the top, front and back edges. Weld along the bottom edges as shown in the picture below.

48. Once the A-pillar tube is securely tacked to the floor plate, we recommend reinforcing the behind dash bracketry by tying the A-pillar tube to

49. Remove the A-pillar assembly from the vehicle and fully weld the tube to the floor plate outside of the Jeep as it is much easier to fully weld

52. Bolt the A-pillar back to the floor and tack into place once satisfied with fitment. Do not fully weld at this time. Repeat A-pillar fitment o

54. After glove box is removed, remove the two 7mm bolts in the image below. Also, remember to remove the lower 7mm bolt on the underside o

56. Once cover plate is removed, undo the two 7mm bolts which secure the grab bar and upper portion of the dash to the behind dash bracketry.

57. From this point, the remaining steps for A-pillar fitment on the passenger side are the sameastheyareforthedriver’sside.Speaker remova

59. If desired, add tube clamps at this time for dash bar removal (Part Number: 3113-150-125). Be sure dash bar is level with the dash and tack int

62. Once everything is welded and cool, deburr welds as needed and weld cage the desired color. Speaker Install 63. Due to the A-pillar location

65. Position the speaker behind the dash as shown below.

66. Position the speaker as desired. Be sure the speaker is clear of touching the A-pillar tube. Also be sure the glove box clears sufficiently.

8. If you are using a rear cage kit, install that section now per the instructions included in that kit. 9. Next, install the A-pillar floor plate

67. If desired, paint the speaker bracket at this time, leaving the edge to be welded unpainted. Reinstall speaker and tack speaker bracket into p

71. After paint, reinstall the interior pieces in the reverse order of removal. Trim interior pieces as needed to clear the tube work. All inter

72. To seal up the A/C ducting, wait until the dash is fully reassembled and remove the two outer A/C bezels. Do this by rotating the vents to ali

Img. 72.2 Release hole rotated 20-30 degrees to align with release tab access hole. 73. Next, using a small flat nose screw driver, push the flat

74. For reference, images 74.1 (locked, secured to dash) and 74.2 (unlocked for removal) show the bezel in both the locked position and unlocked pos

Img. 74.2

 Once removed, seal up the inner vent with a quality duct tape. Ideally use a thick tape with good temperature retention qualities.  See th

75. Steps 73-77 cover stock rocker guard fitment. Other rocker guards may need to be trimmed in specific areas in order to clear cage tie ins. 76.

78. Also, oblong the hole out about 3/8”towards the frame. 79. After trimming, and check fitting that rocker can be installed, coat any exposed

11. Oncemarked,drilloutusinga3/8”drillbit.

80. Repeat rocker modification for other side. Hard top fitment 81. With the addition of the A-pillarcrossbar,thefronthardtoplatchonth

82. Trim off this portion of the latch with a cut off wheel or small body saw. Deburr edges with a file. 83. Install top and close latch. 84. I

12. At this point, it is a good idea to remove any rocker guards installed on the vehicle that may inhibit fitting the cage to frame tie in brackets

Image 14.2 15. Next, cut off the inner edge closest to the frame rail. Be careful not to cut the floor or frame when cutting. 16. Next, clean u

17. Install the 3/8-16UNCx1”boltsas shown with washers under the heads of the bolts, and flange nuts on the underside. Snug hardware down t