Synergy 8009-30 - Jeep JK Front Axle Outer Shell Kit Manuel d'utilisateur

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397 PPM-8009 JK DANA 44 HD FRONT AXLE GUSSET KIT Version 1.0 GENERAL NOTES: • T

17. The side to side location of the new suspension brackets will be measured from the machined edge on the inside of the inner C, next to the weld be

The inside edge of the upper control arm bracket should be 14” front the reference point on the inner C. The front edge of the upper control arm

19. Align the track bar bracket to the axle tube. Once this is aligned you can fully weld to the axle tube. The outside edge of the track bar bra

The front face or bottom surface of the track bar bracket should be level 20. Align and weld the lower control arm brackets. Break the lower co

21. Align and weld the lower shock brackets. Break the lower shock brackets apart. There is a different left and right bracket. When you position

22. Align and weld driver side sway bar link tab. Position the driver side sway bar link tab to the axle. The outside edge of the sway bar link tab

23. Align and weld coil spring mounts. Prep the coil spring mounts to weld to the axle tube, grind the cut edge smooth so it fits the axle tube well

24. Weld inner C gussets. Sand off any paint on the inner C where you will weld the Gussets. There is a left and right lower C gusset; the inner e

25. Weld housing truss. Position the housing truss over the diff housing. Grind off any paint on the housing where you will be welding. You may n

side of the coil mount. This will compensate for the 1/4” thick shell that will go under it. Tag the left and right so you can put them back on the

6. Cut off the lower control arm brackets and shock mounts. These will not be reused so try to cut most of the weld bead off the tube so you will ha

9. We recommend that you weld the axle tubes to the cast center section. Tig welding with stainless 312 or similar dissimilar metal welding ro

10. Prepare the outer tube shells by deburring the inside of the laser cut edge, make sure there is no slag from the laser cut edge on the inside

11. Position the outer tube shells to the axle tube. The holes should be oriented at the top and bottom with the seam at the front and back. Do

12. Weld the seam between the two outer shell halves. The narrow seam is intended to just weld the two shell halves to each other; the wide seam is

14. Weld the outer end of the tube to the inner C 15. Weld the inner end of the tube shell to the cast center section. Tig welding with stainl

16. Place the axle on jack stands on level ground or on a flat work or welding bench. Support the pinion with a jack or something to align the correc