Daystar KC09113BK User Manual

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www.Daystarweb.com

Tech Support Contact Info

[e-mail]

Phone: [phone]

Fax: [phone]

841 South 71st Avenue

Phoenix, AZ 85043

Instruction Sheet: P20165-02

2013 Daystar Products International Inc.

Revision: 02

Revision Date: 10/03/2013

Revised by: TY

2009 & UP KC09113BK FRONT DODGE 1500/4WD

2009 & UP KC09114BK FRONT & REAR Kit 1500/4WD

2009 & UP KC09116BK REAR only KIT 2WD & 4WD

FRONT KIT

REAR KIT

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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
does generally not relate to personal injury. Damage to your product or other

!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” Rachet

Set 1/2” Drive metric socket set

Set Metric wrench set

1 Torque wrench

Bill of Materials / Part list

FRONT KIT KC09113BK

REAR KIT KC09116 BK

Quantity Part Number Description

KC09113

FRONT KIT

2 M03703 Front Coil Spring spacer

6 S11082 Stud Extenders

6 S10292 10mm 1.5 Lock nut elastic

1 P20165 / P10474 Instructions / Warning decal

KC09116

REAR KIT

2 M20119 Rear Coil Spring Spacer

1 P20165 / P10474 Instructions / Warning decal

KC09114

FRONT AND REAR KIT

All Parts Numbers

All parts listed for Front &
Rear kits

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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
in place to support ve­hicle in case jack or vehi­cle shifts.

1. Put the transmission in park or 1st gear for ( manual transmis-

sion ) and chock the rear tires.

2. Raise the front of the truck in accordance to manufacturer rec­ommendations and support with jack stands, chock rear
wheels. Raise vehicle so that the front tire are off the ground.

3. Remove front tires.

4. Remove the sway bar link from sway bar at the frame.

5. Remove the upper ball joint nut and separate the knuckle from

the upper A-arm using the appropriate Puller tool..

6. Remove the lower strut nuts on strut tower (3) per side.

NOTICE: leave one of the nuts on the strut to prevent the strut
from dropping out in the next step.

FRONT SUSPENSION

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7. Remove the lower strut bolt and nut.

8. Remove the strut from the upper strut tower so you can install

the spacer.

9. Install the stud extenders over the stock strut studs.

10. Install the spacer over the stud extenders.

11. Install the strut with the spacer onto the lower strut mount.

Leave the bolt loose.

12. Install the strut to the strut tower. Using a floor jack, raise the

lower control arm and reconnect the strut to the strut tower
using the supplied nuts and washers.

13. Reconnect the upper ball joint to the knuckle.

14. Torque all nuts and bolts to OEM specifications.

15. Install the wheels.

16. Remove jack stands and lower the truck back on the ground.

Remove all jacks and jack stands from under vehicle.

17. Torque the lug nuts to 85ft.lbs. using an X pattern.

!Caution: Have an alignment professional check and adjust
the alignment to factory specifications.

18. 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.

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19. 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.

20. After 25 miles of driving re-torque the lug nuts to 85ft.lbs..

21. 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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REAR SUSPENSION

1. Read instructions completely, verify bill of materials and deter­mine if you have the correct tools before beginning installation.

2. Chock front tires and raise the rear of vehicle placeing jack stands

under the frame rails so the tires are off the ground .

3. Support the rear axle with a floor jack.

4. Remove the rear wheels.

5. On each side remove the lower shock bolt and nut at the axle.

6. Remove the 2 sway bar end link mounting nuts at the axle.

7. Remove the track bar bolt and nut at the axle.

8. Lower the axle and remove the spring and stock spring isolator

pad.

9. Install the lift spacer on the top of the spring with the spring
properly positioned in the spacer helix. The factory isolator is
not re-used.

NOTICE: The rear spacer will press over the factory detent in the

upper spring mount.

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10. Reinstall the spring/spacer assembly into spring seat with the
spacer on top. Be sure the spring and spacer are properly seat­ed on the axle and frame

11. Jack up the axle so you can reinstall the track bar, sway bar

12. Then then double check the installation.

13. Reinstall driver and passenger tires and wheels.

14. Remove jack stands and lower the truck back on the
ground. Remove all jacks and jack stands from under vehi­cle.

15. Torque the lug nuts to 85 ft.lbs. using an X pattern.

!Caution: Have an alignment professional check and ad

just the alignment to factory specifications.

16. With the vehicle on the ground 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.

17. 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.

18. After 25 miles of driving re-torque the lug nuts to 85
ft.lbs..

19. After 500 miles of driving re-torque all of the hardware
associated with the leveling spacer installation to factory

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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”).

Established in 1977

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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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Established in 1977

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