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www.Daystarweb.com
Tech Support Contact Info
Tech@DaystarWeb.com
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71st Avenue
Phoenix, AZ 85043
Instruction Sheet: P21249-01
2013 Daystar Products International
Inc.
Revision: 01
Revision Date: 10/16/2013
Revised by: TY
KC09100BK / KC09103BK
DODGE 1500 1994 - 2012 2 WD.
DODGE 1500 / 2500 / 3500 1994 - 2012
KC09100BK
KC09103BK
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Introduction
is your number one source for Made In The USA quality,
Comfort Ride™ leveling kits. Now backed with our exclusive Go Everywhere © Lifetime Limited Warranty
(see terms at Daystarweb.com). To assure your safety and
proper installation of this product, take a moment to read all instructions and Product Safety Information before trying to install your Daystar® product. Current
OEM suspension design is complex: meaning safe and proper installation requires
understanding OEM service techniques for disassembly and assembly of the components indicated together with the instructions and warnings set out below and in
the OEM service manual and your owner’s manual. Daystar® strongly recom-
mends seeking advice from or having this product installed by a professional mechanic who can inspect your suspension, confirm compatibility with your tire and
wheel choice and, if needed, reset alignment to optimize your steering and the fea-
Product Safety Information
Throughout these instructions important safety information is generally preceded by one of three signal words indicating the relative risk of injury. The
signal words mean:
! WARNING A hazardous situation which, if not avoided, could result in
death or serious injury. You can be Killed or Seriously Hurt if you don’t follow instructions.
! CAUTION A hazardous situation which, if not avoided, could result in
minor or moderate injury. You can be moderately HURT and also may suffer
property damage if you don’t follow instructions.
NOTICE Careful attention is required to this instruction or operation but
!WARNING
Familiarize yourself with all vehicle manufactures’ and Daystar
warnings, instructions and limited warranties before driving your
modified suspension vehicle. Also be aware many states / countries have laws governing on-road vehicle heights and modifications. You are responsible for assuring the safety and legality of
your vehicle. A summary of current state vehicle laws is available
at www.sema.org.
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Tools Needed
Quantity Description
1 Floor Jack
2 Jack Stands
2 Wheel Chocks
1 Lug Wrench
1 1/2” Drive Ratchet
1 1/2” Drive Socket Set
1 Wrench Set
1 Coil Spring Compressor
1 Ball Joint / Tie Rod Separator
Parts List
Quantity Part Number Description
KIT NUMBER
1 M03210BK spacer Kit KC09100BK DODGE
OR
1 M20224BK spacer Kit KC09103BK DODGE
1 P21249-01
Instructions
1 P10474
Driver Warning Decal
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Installation Instructions
!Warning: Always work with appropriate personal safety
gear including safety glasses, gloves and hearing protection if
using air powered tools.
Begin by inspecting the components & hardware for damage. Then compare components & hardware to the bill of materials for completeness. If anything is missing/damaged, do not proceed with the installation. Please, call Daystar Products (800-595-
7659) and we will send you the missing of damaged components
free of charge.
!Caution: Vehicle front end must be raised to install leveling
kit. Using a hydraulic chassis lift will greatly ease installation.
If another jack is used, assure vehicle is level on a firm surface, in park (1st gear), rear wheels blocked and jack stands
IMPORTANT NOTE: The advertised amount of lift that this kit
provides and the thickness of the spacers supplied will not be the
same! For example, a 2-1/2” lift may only have 1-1/2” thick spacers. The reason for the difference between the spacer thickness
and the amount of lift has to do with suspension geometry. There
is a ratio involved, and it is this ratio that determines the thickness
of the spacers. Rest assured, installing the spacer supplied will
1. Check to see that the spacer kit you purchased matches the year
and model of your vehicle. Spacer kits two inches or taller may
require a spring compressor to install. Ball joint and tie rod
forks may also be useful.
2. A good portion of your front suspension will be disassembled
so this would be a good time to replace any worn parts (i.e. tie
rod ends, ball joints, idler arm and any bushings) Replace bushings with polyurethane replacement parts.
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3. Jack up vehicle as high as possible using jack stands for support at all times.
4. With vehicle safely off the ground remove front tires. It is advisable to disassemble on side at a time so that you can use the
other side as a reference for re-assembly .
5. Remove the brake caliper from the rotor (attached with 2 bolts
inside the caliper or with press-in clips depending on the vehicle). Do not remove the brake line from the caliper unless you
intend to bleed the brakes at this time. Set the caliper aside or
tie it up to the frame rail. Avoid pinching the brake line.
6. Remove the tie rod from the spindle using the proper tools. Do
not hit the tie rod itself or the nut on the threaded portion of the
tie rod or it may cause damaged and need replacing.
7. Remove the anti-sway bar from the lower control arm. This
would be a good time to replace the end link bushings with polyurethane replacement bushing.
8. If your vehicle is equipped with anti-lock brakes you must
now disconnect the front rotor sensor from the dust shield or
spindle and set it aside.
9. Disconnect your shock absorber completely from the vehicle
whether it is mounted inside the coil spring or not.
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10. Support the lower control arm with jack just touching the arm.
This will prevent it from dropping when the ball joint is disconnected.
11. The use of a coil spring compressor is recommended before the
following steps are taken. CAUTION: Spring will be under ex-
treme compression use caution when removing.
12. Disconnect the upper ball joint from the top of the spindle using
the proper tools. Do not hit the ball joint or the threaded end of
the ball joint. Once the ball joint is free the spindle should move
easily.
13. Be careful when lowering the lower control arm. The coil spring
is under high compression and may shift when released. CAU-
TION: Do not stand near the side of the truck during this step.
Lower the jack so that the lower control arm swings down. If the
coil spring has not fallen out on it’s own you may need to use a
pry bar from the front of the vehicle to remove it.
14. NOTICE: Which end of the coil spring is “bottom” for installation. Also note the depression in the lower control arm. It is important that the last winding of the coil spring fit into the indentation completely so that the vehicle will sit level.
15. NOTICE: Do not switch coil springs from side to side as some
vehicles have a specific “right” and “left” coil spring.
16. Check the coil spacer for proper fitment into the coil spring
mount in the frame. The flat part of the spacer should face up and
touch the top of the spring mount. Some vehicles have guiding
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17. Install the coil spring with the spacer on top of it. If you used a
coil spring compressor it should still be on the spring in a compressed state. If not you may need to compress the spring before re-installing. Make sure the spacer is centered in the upper
mount and the bottom of the spring is properly nested in the
receptor groove on the lower control arm. If you are installing a
two-inch or taller spacer you may need a spring compressor.
CAUTION: Follow all safety rules when installing the coil
spring as it will be under extreme compression.
18. Raise the lower control arm with a jack once the coil spring
and spacer are properly lined up. Raise until the spindle is high
enough to bolt on the upper ball joint. Before bolting on the
upper ball joint make sure the brake caliper and brake line are
where they need to be since some brake lines run inside the
spindle and outside the coil spring.
19. With the upper ball joint tight and a cotter pin re-installed you
may now remove the jack from under the lower control arm.
20. Assemble all of the components previously removed (sway bar
with new polyurethane bushings, tie rod ends with polyurethane grease boot, brake caliper and anti-lock sensor). Don’t
forget the shock with a new colored boot while it is off.
21. Repeat instructions for other side.
22. Then then double check the installation and torque all bolts to
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23. Remove jack stands and lower the truck back on the ground.
Remove all jacks and jack stands from under vehicle. Torque
the lug nuts to 85 ft.lbs. using an X pattern
24. With the vehicle on the ground cycle the steering wheel side
to side and inspect suspension components, brake lines and
tires to ensure there are not any clearance issues. Jounce the
suspension to assure front suspension operates freely, brake
lines retain proper slack at full extension and that they remain clear of springs or other obstructions.
Your vehicle may sit too high at first because the suspension
needs to settle. NOTICE: drive vehicle for at least 25 miles
for suspension to settle in to proper ride height.
Caution: Have an alignment professional check and adjust the
alignment to factory specifications.
25. Install “Warning to Driver” decal on the vehicle’s sun visor or dash. The decal must be placed in a conspicuous location. Anyone that operates the vehicle must be made aware
of the changes made.
26. After 25 miles of driving re-torque the lug nuts to 85 ft.lbs.
27. After 500 miles of driving re-torque all of the hardware associated with the leveling spacer installation to factory specifications. Repeat torqueing procedure as required.
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Daystar® Lifetime GoEverywhere Limited Warranty
Your Daystar® Comfort Ride or Budget Boost leveling kit is covered by the
following Go Everywhere Lifetime Limited Warranty provided exclusively
by Daystar Products International, Inc., 841 South 71st Ave., Phoenix, AZ
85043 (“Daystar”).
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What is Covered? Real Life Use, Off Road & On: Subject to the terms,
exclusions and limitations herein, Daystar® warrants to the initial retail purchaser that your Comfort Ride™ or Budget Boost™ leveling kit shall be free
of defects in material and workmanship for so long as it is properly installed on
a single vehicle owned by the initial retail Daystar® purchaser.
What is Not Covered? Your Vehicle & Parts Not Daystar’s GoEverywhere:
Your Daystar Limited Warranty does not cover: (a.) damage to your vehicle,
vehicle systems (ex. electronic stability control) other products, components or
property not manufactured by Daystar to our exclusive GoEverywhere standards, (b.) customer choice of vehicle configuration/tire and wheel combinations contrary to Daystar® recommendations, warnings or applicable laws,
(C.) Acts of God, weather, corrosion, accidents, theft, vandalism, negligent
misuse or intentional damage, other exclusions under your OEM Limited Warranty.
Remedy Limited to Repair/Replacement. Get back on your favorite trail
fast. The exclusive remedy provided hereunder shall, upon Daystar’s inspec-
tion and option, be either repair or replacement of the Comfort Ride™ or
Budget Boost™ leveling kit or parts covered under this Limited Warranty.
Call us and we will get you back wheelin’ (623/907-0081). All labor, removal,
shipping and installation costs are customer’s responsibility.
Other Exclusions –Limitation of Damages - Your Rights Under State Law.
Stuff Lawyers Say.
At Daystar® we aren’t big fans of lawyers, even ours. Still, he says our Limited Warranty has to include this stuff. In consideration of the purchase price
paid, neither Daystar® nor any independent Daystar® distributor or repair person are responsible for any time loss, loss of vehicle use, rental costs, transportation, labor or for any incidental, consequential, punitive or other damages
you may have or incur in connection with any part or product purchased. No
Daystar® employee or independent distributor is authorized to make any statement or representation altering the terms of Daystar’s GoEverywhere Lifetime
Limited Warranty. Your exclusive remedy hereunder for covered parts is
repair/replacement as described above. This Limited Warranty gives you
specific rights. You may also have other rights that vary from state to state. For
example, some states do not allow limitations of how long an implied warranty
lasts and/or do not allow the exclusion or limitation of incidental or consequential damages, so the limitations and exclusions herein may not apply to you.
All other warranties are hereby disclaimed, except to the extent prohibited by
applicable law in which case any implied warranty of merchantability, fitness
for a particular purpose or other implied warranty are limited to a period of
four (4) years from date of initial retail purchase. Daystar® reserves the rights
to: (a.) require invoice or other proof of purchase; (b.) make future revisions to
these products and Limited Warranty without prior notice or obligation to
upgrade your Daystar® product.
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