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Established in 1977
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KG04501BK
2004 to 2011 HUMMER H3 and H3T
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: P20166-02
2013 Daystar Products International
Inc.
Revision: 2
Revision Date: 09/09/2013
Revised by: TY
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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. Day-
star® strongly recommends 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 features of your Daystar® Comfort Ride kit.
We are here to help if you have remaining technical questions after reading
Introduction
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 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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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.
© Daystar Products International, Inc., 9.15.13. All rights reserved.
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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”).
21. Remove all jacks and jack stands from under vehicle.
22. Center the steering wheel.
23. 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.
24. 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.
25. After 500 miles of driving re-torque all of the hardware
associated with the Body lift spacer installation to 75 ft
lbs. In the same criss cross pattern. Repeat torqueing pro-
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Part List
Quantity Part Number Description
12 M20166-BK 1” Body Lift Spacer
4 M20176-BK 1” Bed Support
Spacer
12 M14-20X160
10.9
Bolts & Loc – Tite
(red)
4 M14-20X90
10.9
Bolts & loc -- Tite
(red)
16 Flat Washer / Decal
Bill of Materials
Tools Needed
Quantity Description
2 Frame Jack Stans
2 Floor Jack
1 22 mm Socket
1 19mm Socket
1 Short socket Extension
1 Long socket Extension
1 1/4” Ratchet
1 1/2” Ratchet
4 Wheel Chocks
1 Tape Measure
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!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 body must be raised to install Body lift 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.
H3T 1” DAYSTAR BODY LIFT and 2” TORSION KEY KIT with 37” TIERS
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NOTICE: Double check all of the installation,
Top of Fan Shroud
The top of the fan shroud will also need to be trimmed so that air intake tube does
not rub. Trim the section where the air intake tube is touching on top of fan
shroud. Trim just enough so it clears.
Back of engine cover
The back of the engine cover is going to need trimming so there is no contact
from the heater hose that are running into the firewall. You will want to make
small cuts to the engine cover until you have clearance.
The heater core hoses run from the front of the motor to the fire wall. Locate the
bracket that is on the passenger side cylinder head, loosen and adjust the bracket
counter clockwise approximately 1.5” this will give you additional clearance
from the fan shroud.
Prior to Starting or driving your Hummer you will want to check all of the brake
lines, parking brake cables, and hoses underneath of the vehicle. You will want
to make sure they are not pulled out, bond up, kinked, or too tight. This must be
Trim fan
Air intake tube
Trim RT corner
of engine cover
Heater hose bracket
Passenger side
Remove
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Bed Support Pads ( H3T ONLY)
There are four Bed Support Tabs supplied in the kit, you will need to install these
when you are installing your body lift spacers for the bed. The location of where
these will go is just behind the front bed spacers, and just in front of the read bed
spacers. You will want to remove the factory clear isolators and replace with supplied bed support spacers
When you have installed all of your 1” body spacers you will want to go around and
snug up all of the bolts in a criss cross pattern, but do not tighten.
Now is the time where you will want to adjust your bed and body back to the measurements you took in the beginning. You may want to use a pry to gently pry the
body back into place. NOTICE: Do not pry on outer body.
Apply padding
prior to any prying of undercarriage to protect painted surfaces.
Once your body and bed have been re-adjusted you will want to torque all the bolts to
75ftlbs in the same criss cross pattern.
After you have torque
Loosen then
Install spacer
Measure and
adjust
Remove clear
isolators &
install new bed
spacer
FOR PICKUP
BED ON H3T
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Installation Instructions
Hummer H3T Body Lift
Fan Shroud
The Factory Fan Shroud is a two piece design you will need to remove the lower
half of the fan shroud so that it can be trimmed.
1. locate the two center push tabs on the sides of the shroud (upper fan shroud),
depress these to loosen the lower portion of the shroud from the Top Portion
2. On the bottom of the fan shroud remove the push in style radiator hose supports,
(careful not to damage as you will re-use them) Pull the radiator hose back.
3. Depress the two tabs at the bottom of the fan shroud; with the shroud loose at the
top and bottom pull the shroud down. The Fan Shroud at this time should be free
and able to move.
4. Turning the Fan shroud up in a Counter clockwise position and pulling down on
the shroud will allow for removal.
Trimming the Fan Shroud
5. With the fan shroud out and on a flat surface (lip facing up) you will want to
make a line from the Top Part of the lip, on the Outside portion of the shroud.
The line is to be a 1/4 inch out from the top lip.
6. The 1/4” line is to go all the way around the shroud; this is your cut line.
7. Trim the Shroud
8. A 3/8” hole will need to be drilled a half inch up from the bottom center of the
fan shroud.
9. After you make the cut you will want to debur all edges
10.When cutting and deburing are finished, reverse the step of removal to reinstall
the shroud.
11.When the Fan Shroud is re-installed place supplied push on hose support into
the new hole that was drilled. This is an additional support for the radiator hose.
tab
Hose
support
Lower tabs
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Body Measurement
Prior to installing your new Daystar Body Lift you will need to take body to
frame, bed to frame rail measurements and measure the gap between the body and
bed. These measurements are what you will need to adjust your body and bed
back to after installing your Body Lift.
When measuring the body you will want to measure down the drivers side and
passenger side in three different locations.
13. In front of the tire
14. Middle of the vehicle (at the front door and rear door seam)
15. The back of the body (where the bed and body separate)
We recommend you take the body measurements from the lowest point on the
body and the outside of the frame rail. (If you choose to use different locations for
measuring be sure that you use the same reference points on both sides)
The bed will require two measurements down the drive side and passenger side as
well. You will want to measure at the front of the bed where the bed and body
separate and at the back of the bed just behind the drive tires. You should use the
same measuring points as you did on the body.
Measure
Trim off 1/4”
Measure
Measure rear
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Bumper Cap
The Rear Bumper Cap will require removal and trimming of the two triangle tabs
on top side of the bumper cap. To remove the cap simply pop the two plug caps at
the top and remove the screw using a Phillips head screw driver. You will then
want to go underneath of the bump cap and remove the torx head screws, once
loose locate the push style clips on the back side of the bumper cap, depress and
slightly pry up on the bumper cap.
Once the bumper cap is removed trim the triangle tabs on the top side, and debur.
Simply reverse these instructions to re-install the bumper cap.
Body Lift Install
When installing your new Body Lift Spacers be sure to only do one side at a time.
You will want to loosen the opposite side that you are working on just enough so
that you can raise the side you are working on up to slide in your new spacers.
Drive / Passenger Side Installation
You want to raise the driver side with caution so that you do not over extend the
steering shaft!
Remove cap
and screw
Trim off
triangle tab
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