Synergy DL flip adapter

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BertaNation

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I am installing the synergy drag link and adapter with no success. Drilled out my oem knuckle w to 7/8 with a step bit. Installed the synergy tre adapter. Had to give it a light tappy tap to get it in. Installing the tre did not go so well. Would not push into the adapter easily so I put an oversized socket over the top to give it a little persuasion. Got it down far enough to catch a couple threads w the castle nut. Thought I could bring the tre down w the castle nut. It's not working out. I got several turns out of it but it is definitely to tight and I am afraid that if I keep going something is going to get damaged. Any thoughts???
2015 jku
IMG_1477277157.782873.jpg


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Before you installed the insert, did you happen to put it on the tapered stud to see if it fit? Since it is sold in a kit like that, you would think that parts are all correct.
 
I had the same issue with mine and just kept cranking until I could get the cotter pin in. Ended up selling the whole kit and now have EVO DL flip. :thumb:
 
WJCO said:
Before you installed the insert, did you happen to put it on the tapered stud to see if it fit? Since it is sold in a kit like that, you would think that parts are all correct.
Click to expand...

No I didn't pre fit it. Didn't even cross my mind.
I have read a few threads about fitment issues with the adapter to the knuckle. But nothing concerning the tre to the adapter.


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Very carefully open up the hole a little more with a die grinder or dremmel. I mean very carefully. Little at a time you absolutely do not want to over bore it. I think synergy has a thicker adapter if you go too much but better to go a little at a time and test fit. It won't take much.


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A.J. said:
Very carefully open up the hole a little more with a die grinder or dremmel. I mean very carefully. Little at a time you absolutely do not want to over bore it. I think synergy has a thicker adapter if you go too much but better to go a little at a time and test fit. It won't take much.


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Click to expand...

Do this! I had to do the same thing with mine. Just slowly stepped the hole diameter up until I could get a full nut and the cotter key installed. I thinking took me at least 5 times before everything went together like it should.


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A.J. said:
Very carefully open up the hole a little more with a die grinder or dremmel. I mean very carefully. Little at a time you absolutely do not want to over bore it. I think synergy has a thicker adapter if you go too much but better to go a little at a time and test fit. It won't take much.


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Click to expand...

What kind of bit do u suggest for the dremel. I have a carbide metal cutting bit on it currently. Think that will be ok?


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BertaNation said:
I am installing the synergy drag link and adapter with no success. Drilled out my oem knuckle w to 7/8 with a step bit. Installed the synergy tre adapter. Had to give it a light tappy tap to get it in. Installing the tre did not go so well. Would not push into the adapter easily so I put an oversized socket over the top to give it a little persuasion. Got it down far enough to catch a couple threads w the castle nut. Thought I could bring the tre down w the castle nut. It's not working out. I got several turns out of it but it is definitely to tight and I am afraid that if I keep going something is going to get damaged. Any thoughts???
2015 jku
View attachment 228230


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Click to expand...

Insert should just drop in, if you had to hit it in the hole is not big enough.
 
BertaNation said:
I am installing the synergy drag link and adapter with no success. Drilled out my oem knuckle w to 7/8 with a step bit. Installed the synergy tre adapter. Had to give it a light tappy tap to get it in. Installing the tre did not go so well. Would not push into the adapter easily so I put an oversized socket over the top to give it a little persuasion. Got it down far enough to catch a couple threads w the castle nut. Thought I could bring the tre down w the castle nut. It's not working out. I got several turns out of it but it is definitely to tight and I am afraid that if I keep going something is going to get damaged. Any thoughts???
2015 jku
View attachment 228230

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Click to expand...

It says you used a step bit to drill the knuckle. Did you finish drilling the hole straight with a regular straight bit?
 
Journeyman said:
If I remember right the directions say to use a step bit of your not using an adaptor if using the adaptor drill with straight 7/8 bit.


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Click to expand...

OK. In your photo, I see the top of the silver adapter. You may want to contact Synergy to clarify the instructions.

If you are using a tapered bit, then you don't need the adapter. The tapered bit is not the same as a step bit. The tapered bit is manufactured at the same taper as the end link taper. It looks like you are using an adapter.
 
Last edited:
Jeepfan30 said:
I had the same issue with mine and just kept cranking until I could get the cotter pin in. Ended up selling the whole kit and now have EVO DL flip. :thumb:
Click to expand...
A.J. said:
Very carefully open up the hole a little more with a die grinder or dremmel. I mean very carefully. Little at a time you absolutely do not want to over bore it. I think synergy has a thicker adapter if you go too much but better to go a little at a time and test fit. It won't take much.
Click to expand...

Syngery was tough for me too and I used a dremel afterward. My synergy insert was a bit loose when I was done and it still took alot of force to get the castle nut on far enough to use a cotter pin. Effort involved was significant for a little task (and it made me nervous the whole time) but, I have had zero problems with it.
 
I had the same problem and as mentioned I kept on tightening until I got the pin through. After about 6 months with it I have to say I hate synergy drag link. For some reason it gets out of alignment very easily. I have jam nut sold and the clamp bolt tightened fully and still same shit. I plan on getting the Currie down the line.

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You shouldn't be tapping it at all if drilled to the correct size. I didn't use a unibit. I kept the bit and hole lubed while I ever so slightly making the hole larger if needed. The directions clearly state not to hammer it in...it should drop in.
 
kpig said:
It says you used a step bit to drill the knuckle. Did you finish drilling the hole straight with a regular straight bit?
Click to expand...

The step bit went up to 7/8. I was able to go all the way through with it. Pulled it back apart and going at it with a dremel to enlarge it a little at a time. Almost got it where I need it.


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sblackf1 said:
Syngery was tough for me too and I used a dremel afterward. My synergy insert was a bit loose when I was done and it still took alot of force to get the castle nut on far enough to use a cotter pin. Effort involved was significant for a little task (and it made me nervous the whole time) but, I have had zero problems with it.
Click to expand...

That helps. I have used the dremel enough to were the adapter almost slips in without assistance. And it still takes quite a bit of force to tighten the nut.


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Jackal01 said:
You shouldn't be tapping it at all if drilled to the correct size. I didn't use a unibit. I kept the bit and hole lubed while I ever so slightly making the hole larger if needed. The directions clearly state not to hammer it in...it should drop in.
Click to expand...

Guess I didn't get that far on the instructions. I just read drill to 7/8 and install the adapter.
Drilled it slow with lube and made the hole 7/8.


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rogerk93 said:
I had the same problem and as mentioned I kept on tightening until I got the pin through. After about 6 months with it I have to say I hate synergy drag link. For some reason it gets out of alignment very easily. I have jam nut sold and the clamp bolt tightened fully and still same shit. I plan on getting the Currie down the line.

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Click to expand...

I've had this same problem. But it's never the drag link, it's my ball joints and unit bearing that usually cause my problems. I just replaced my bearings and ball joints and bam [emoji457] everything's perfect again.


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