Issue with Synergy Adjustable Rear Upper Control Arms

[Moto_21]

You adjust them once, and you never see them again unless your changing lifts…which is not something you do that often… unless you’re @Moto_21 ……..

Thank you ???

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[Headbarcode]

3.5" Teraflex coil lift.

My 1st setup was the Dynatrac Endurosport true 2" lift, which I completed with all 8 control arms and rear track bar from synergy. Front end was all Steersmarts. All was good, but I wanted bigger. That led me to Metalcloaks 3.5" lift.

I thought I could continue using the arms, but that didn't work out. After just a couple of flex tests at work, I started noticing some handling issues as it's also my daily driver. I was under it a dozen times, quadruple checking everything and not finding a culprit. Knowing it had to be a bad bushing somewhere, I decided to start checking and the lower front control arms seemed like the most logical spot to start.

Turned out to be the tie rod end spinning in the adjuster bushing. The thing is, I checked them after the antiseaze treatment just like you and they were all soild. I loosened the pinch bolt and retorqued it to 90, but it wasn't as solid. I have a long pry bar with a pointed end that I use to misalign the bushing to check a pinch bolt or jamb nut. It took 110 on the pinch bolt to make it right again. The Jeep was back to driving like a dream, so I went back to keeping UPS busy.

A short time later, after another flex test, the same driving issue started to crop up again. I put it back up on the forks so I could see what the control arms looked like. In this pic, the front right tire was 40" off the ground and the back axle was still a couple of inches away from fully into the bumpstops.

I pulled the arms and retorqued, but couldn't get them solid before the slot in the bar became fully collapsed right at the pinch bolts. A few weeks later and all 8 synergy arms were put into a Metalcloak control arm box that's still sitting in my garage. The front and rear uppers were still OK, but both pairs of lowers were spinning under the clamping force due to not having enough misalignment in the bushing ends. All this babble is just a heads up to keep an eye on them. They were definitely not made to handle a lot of flex.

 

[Ran4]

My 1st setup was the Dynatrac Endurosport true 2" lift, which I completed with all 8 control arms and rear track bar from synergy. Front end was all Steersmarts. All was good, but I wanted bigger. That led me to Metalcloaks 3.5" lift.

I thought I could continue using the arms, but that didn't work out. After just a couple of flex tests at work, I started noticing some handling issues as it's also my daily driver. I was under it a dozen times, quadruple checking everything and not finding a culprit. Knowing it had to be a bad bushing somewhere, I decided to start checking and the lower front control arms seemed like the most logical spot to start.

Turned out to be the tie rod end spinning in the adjuster bushing. The thing is, I checked them after the antiseaze treatment just like you and they were all soild. I loosened the pinch bolt and retorqued it to 90, but it wasn't as solid. I have a long pry bar with a pointed end that I use to misalign the bushing to check a pinch bolt or jamb nut. It took 110 on the pinch bolt to make it right again. The Jeep was back to driving like a dream, so I went back to keeping UPS busy.

A short time later, after another flex test, the same driving issue started to crop up again. I put it back up on the forks so I could see what the control arms looked like. In this pic, the front right tire was 40" off the ground and the back axle was still a couple of inches away from fully into the bumpstops.

I pulled the arms and retorqued, but couldn't get them solid before the slot in the bar became fully collapsed right at the pinch bolts. A few weeks later and all 8 synergy arms were put into a Metalcloak control arm box that's still sitting in my garage. The front and rear uppers were still OK, but both pairs of lowers were spinning under the clamping force due to not having enough misalignment in the bushing ends. All this babble is just a heads up to keep an eye on them. They were definitely not made to handle a lot of flex.

Thanks for this post, Mike. I'll surely be watching the arms now that you've confirmed my concern. A friend suggested (somewhat facetiously) that we just weld the ends on the ones I'm having an issue with. Obviously, that would eliminate the main reason for hqving adjustable control arms in the first place. But I guess it would save me from having to buy new ones. After all, as pointed out by @Roky , once you have them dialed in, you should be good for a while. The rear uppers I was having an issue with are on their way back to Synergy for inspection and to be rebuilt and returned to me. I guess we'll see how that pans out. For now, I've left the stock rear uppers installed, and have the rear lowers set at stock length until this matter is resolved. I'll post here when I get the arms back. Thank again, Mike..

 

[Headbarcode]

Thanks for this post, Mike. I'll surely be watching the arms now that you've confirmed my concern. A friend suggested (somewhat facetiously) that we just weld the ends on the ones I'm having an issue with. Obviously, that would eliminate the main reason for hqving adjustable control arms in the first place. But I guess it would save me from having to buy new ones. After all, as pointed out by @Roky , once you have them dialed in, you should be good for a while. The rear uppers I was having an issue with are on their way back to Synergy for inspection and to be rebuilt and returned to me. I guess we'll see how that pans out. For now, I've left the stock rear uppers installed, and have the rear lowers set at stock length until this matter is resolved. I'll post here when I get the arms back. Thank again, Mike..

You're definitely best off starting with a known good set that properly torques down, than to weld a bad one into submission. Even the best weld would still keep those arms in the forefront of my mind, constantly wondering what thread was cut to deep and if that weld was also acting like a fulcrum surrounded by loose threading.

I'm looking forward to hearing about a solid replacement set.

Cheers, buddy!

 

[Ran4]

Synergy has had the 'bad' control arms in their possession for a week as of today (Oct 14). Neither Northridge or myself have heard a word from them despite efforts to contact them. To say the least, I'm pretty disappointed.

 

[kosinar]

Synergy has had the 'bad' control arms in their possession for a week as of today (Oct 14). Neither Northridge or myself have heard a word from them despite efforts to contact them. To say the least, I'm pretty disappointed.

I just installed lower front control arm last weekend. I was able to install 1 1/2 left hand jam nut between adjuster and head of the bushing. I torqued pinch bolt to 90 ft. Lb and jam nut as tight as I could. Will see if that will keep everything tight.

 

[Moto_21]

Synergy has had the 'bad' control arms in their possession for a week as of today (Oct 14). Neither Northridge or myself have heard a word from them despite efforts to contact them. To say the least, I'm pretty disappointed.

Wonderful world of shitergy

 

[Ran4]

I just installed lower front control arm last weekend. I was able to install 1 1/2 left hand jam nut between adjuster and head of the bushing. I torqued pinch bolt to 90 ft. Lb and jam nut as tight as I could. Will see if that will keep everything tight.

Where did you locate jam nuts for the Synergy arms? That's not a bad idea. We sure shouldn't 'need' to go that route (kinda defeats the purpose of having the adjuster sleeve), but at least it's a way to deal with the problem. I'll be interested to know how it holds up for you..

 

[word302]

Where did you locate jam nuts for the Synergy arms? That's not a bad idea. We sure shouldn't 'need' to go that route (kinda defeats the purpose of having the adjuster sleeve), but at least it's a way to deal with the problem. I'll be interested to know how it holds up for you..

The reality is the pinch bolt setup from any manufacturer is just not going to hold up over time. Jam nuts are the only way to go, especially on control arms and track bars.

 

[DeadHead]

They were having this same problem with their drag link, back in the day, don’t know if they ever resolved it. I haven’t had any trouble with their tie rod, but I’ve got yeti drag link. I’m not a fan of adjustment sleeves and pinch bolts, especially on control arms. I never understood the whole “ it’s adjustable on the vehicle” thing. You adjust them once, and you never see them again unless your changing lifts…which is not something you do that often…….…

They didn't fix it. I have one of their drag links and it's just junk. Less than 2 months and both ends failed and the pinch bolt is so sloppy it will not hold an alignment going down the road. To make it worse when I contacted them I was told I over greased it and damaged it.

So no they didn't fix it.

 

[Roky]

They didn't fix it. I have one of their drag links and it's just junk. Less than 2 months and both ends failed and the pinch bolt is so sloppy it will not hold an alignment going down the road. To make it worse when I contacted them I was told I over greased it and damaged it.

So no they didn't fix it.

That sucks man, it seems their customer service has really gone to shit. I had good experience with them pre-covid but haven’t heard anyone having good experience with them since…….

 

[kosinar]

Where did you locate jam nuts for the Synergy arms? That's not a bad idea. We sure shouldn't 'need' to go that route (kinda defeats the purpose of having the adjuster sleeve), but at least it's a way to deal with the problem. I'll be interested to know how it holds up for you..

McMaster.com 99612A204 $10.29

 

[Ran4]

McMaster.com 99612A204 $10.29

Thank you!

 

[Northridge4x4]

Synergy has had the 'bad' control arms in their possession for a week as of today (Oct 14). Neither Northridge or myself have heard a word from them despite efforts to contact them. To say the least, I'm pretty disappointed.

I know Molly from my team is all over it but unfortunately we are at the mercy of the MFG who makes the product and who carries the warranty. I can assure you Molly will get with you the minute she hears something

 

[Ran4]

I know Molly from my team is all over it but unfortunately we are at the mercy of the MFG who makes the product and who carries the warranty. I can assure you Molly will get with you the minute she hears something

Thanks. Yes, Molly and I spoke again today (in addition to the 48 emails we have thus far exchanged). While I appreciate the efforts that have been made, I'm nevertheless frustrated by the delay in rectifying this matter.

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