Daystar KG09121 User Manual

Instruction Form #P20516-01

Daystar Products International

841 S. 71

Phoenix, AZ 85043

800-595-7659 toll-free

623-907-0081 local

623-907-0088 fax

www.daystarweb.com

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Rear Block Kit Instructions

Thank You for Choosing Daystar

Daystar recommends a certified technician install this system . In addition to these instructions ,
professional knowledge of disassemble/reassembly procedures as well as post instruction checks must
be known. Attempts to install this system without this knowledge and expertise may jeopardize the
integrity and/or operating of the vehicle.

Please read all the instructions before beginning the installation. Be sure you have all the needed parts
and understand where they go. If anything is missing, do not proceed with the installation, Call Daystar
Products to obtain needed items.

Installation Procedure

1. Place the vehicle on a flat, level surface and set the parking brake. Raise the rear of vehicle with a
floor jack positioned under the rear axle. Place jack stands under the frame rails, a few inches in front of
the rear springs’ front hangers. Ease the jack down until the frame is resting on the stands. Keep a slight
load on the jack. Chock front tires.

Remove the tires. Unbolt the shock absorbers from the axle.

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3. Remove the spring-to-axle U-bolts. Use the jack to carefully lower the axle down enough for block
installation. Do not overextend the brake and axle vent hoses, or any wiring.

4. When a vehicle is factory equipped with lift blocks, generally the factory blocks have an arm that acts
as a contact point for the compression travel stop. The supplied blocks should be positioned
UNDERNEATH the factory blocks.

5. Inspect the block-to-spring perch contact area. The spring perch must be perfectly flat in order for the
blocks to seat properly. If the perches are not perfectly flat, they must be repaired or replaced before
continuing.

6. Be sure the spring perches are clean and free of debris. Inspect the supplied lift blocks; if there is a
taper present in the block, position the bloc k so that the “tall” end of the taper faces rearward and the
“short” end faces forward. Be sure that the spring centering pin(s) are seated properly in the hole(s) of
the blocks, and that the block pin seats properly in the spring perch. Position the spring-to-axle U-bolts
and install the furnished U-bolt flat washers using the stock U-bolt retaining plate. Evenly tighten the U­bolts using an “X” pattern.

½” U-bolts…….75-80 ft-lbs.
9/16” U-bolts….85-90 ft-lbs.
5/8” U-bolts……90-110 ft-lbs.

7. Install the new shock absorbers or reconnect old shocks (if applicable). Reinstall tires and torque to
factory specifications. Lower the vehicle to the floor.

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Instruction Form #P20516-01

8. Check the length of the brake hose, axle vent hose, parking brake cables, and so on for adequate
slack with the suspension hanging at full extension travel.

9. Re-torque the U-bolts after 100 miles and periodically thereafter.

Important Product Use Informatio n

As a general rule, the taller a vehicle is the easier it will roll. We strongly recommend , because of rollover
possibility, that Seat belts and shoulder harness be worn at all times. Avoid situations where a side
rollover may occur.

Braking performance and capabilities are decreased when significantly large/heaver tires and wheels are
used. Take this into consideration while driving, also , speedometer recalibration is necessary when
larger tires are installed.

Do not add, alter, or fabricate any factory or after-market parts which increas e ve h icle hei ght ov er the
intended height of the Daystar Product purchased. Mixing component brands, lifts, and/or combining body
lift with suspension lift voids all warranties. Daystar makes no claims regarding lifting devices and
excludes any and all implied claims. We will not be responsible for any products that are altered.

Notice to Dealer and Vehicle Owner

Any vehicle equipped with any Daystar Product must have the “Warning to driver” decal installed on the
sun visor or dash. The decal is to act a constant reminder for whoever is operating the vehicle of its
unique handling characteristics. INSTALLING DEALER— Its is your responsibility to install the warning
decal and forward these instructions on too the vehicle owner for review and to be kept in the vehicle for
service life.

After installation occurs, a qualified alignment facility is required to align the vehicle to factory specs.

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