Synergy 8012-01 - JK, TJ/LJ, XJ, ZJ D30/44 Inner Axle Sleeve Kit - Manual (Page 4)

14. Repeat the hole pattern for the back/underside of the housing. There should be a total
of 16 hole locations.
15. Center punch all hole locations and drill with a 1/2” drill bit.
16. Remove all paint around the hole surface, around the axle center section where the
axle tubes press in, and at each end of the axle tube where the inner C presses on to
the housing.
17. Remove all metal shavings from both sides of the axle housing after drilling and
grinding. A telescoping magnet or long rod with a 1 ½” radius tab welded at 90
degrees can be used to scoop out the shavings.
18. When all the metal shavings are removed, slide in the new inner axle sleeves until
they are flush with the end of stock axle tube. See figure 4
Figure 4
19. With the paint removed from the inner C, weld around the stock axle tube to the new
Inner Sleeve. As seen in Figure 4.
20. We recommend that you weld the cast iron center section to the stock axle tubes. The
best method is to TIG weld with stainless 312 rod with a slight amount of pre-heating.
Another option is to MIG weld with a little pre-heating. See Figure 5