User guide

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA [phone]
HEAVY DUTY BALL JOINTS
DODGE 00-02 DANA 60
PPM-4124
PPM-4124-01
Version 1.3
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.
• Refer to the factory service manual for general installation instructions for ball joints,
these are no different, any important differences are noted below.
• A special ball joint C-frame press and adapters are required for installation. OTC
and Miller special tools have quality tools available.
• Lubricate the ball joints at every oil change using Synergy High Performance
Chassis & Bearing Grease (PPM-4119).
• These HD ball joints carry a 12 month unlimited warranty. Available to the original
purchaser from the date of purchase and are non transferable.
1. Remove the boots prior to installation to prevent damage. Do not forget to reinstall
them prior to installing the knuckles
2. Orient the lower ball joint so the grease fitting is pointing forward when installing.
3. Install the ball joints using the factory service manual as a guide. Torque the lower
ball joint nut to 35 ft-lbs, and then tighten the upper ball joint nut to 70 ft-lbs. Further
tighten to align the cotter key hole on the upper ball joint, do not loosen to align the
cotter key.
4. Re-torque the lower ball joint nut to 140-160 ft-lbs, again further tighten to align
cotter key hole.
5. Wait until the ball joints are installed to install the grease zerk fittings.
6. Recheck caster on vehicle after new ball joints have been installed as worn ball joints
could result in an increase in actual caster due to excessive play.
Misc torque specs for front end work:
• Unit bearing to knuckle – 120-150 ft-lbs
• Brake Caliper Mounting bolts – 275 ft-lbs
• Tie rod end to knuckle – 80 ft-lbs