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KT09102 1995.5-2004 Toyota Tacoma 2 ½” Lift Kit With 6 Lug
2WD/4WD
Part No. Description Qty.
M02233 End Link Bushing 4
M03112 Bump-stop 4
M00337 Shock/Strut Boot 4
M03271 Coil Spring Spacer 2
M03272 Coil Spring Isolator 2
M03377 Frame Bushing 4
M03245 Spring Bushing 4
M03274 Exhaust Hanger 1
Bill Of Material
S10462 Shackle 2
S10233 18mm-2.5 x 150mm Bolt 2
S10204 18mm-2.5 Nut 4
S10762 M10-1.25X 50mm Stud 6
S10518 10mm Nylock Nut 6
S10231 18mm-2.5 x 110mm Bolt 2
P01055 Cable Tie 4
P10027 Grease Pack 2
Bill Of Material
S10518
1. Read complete instructions before beginning installation, the
following special tools are recommended: Coil spring compressor,
STRUT
TOWER
M03271
STRUT
ASSY.
16. Decompress the coil spring in the strut assembly. Make sure that the spring is seated correctl y into the strut
assembly alignment indentation at the bottom of the strut and the top isolator.
17. Slide the coil spring spacer M03271 onto the top of the strut assembly over the 10mm studs.
18. Install the strut assembly into the strut tower and start the upper three 10mm lock nuts S10518. (Make sure that
the bottom of the strut is aligned as well)
19. Install the lower strut bolt in the original position and torque to 100 foot-pounds. (Step 8)
20. Using the floor jack, raise the lower control arm and connect the upper ball joint on the upper control arm to the
spindle. Torque nut to 80 ft lbs. and make sure that you replace the cotter pin. (Not supplied)
21. Install the supplied sway bar end link bushings M02233.
22. Remove and replace the bump-stops with a pair of Channelocks. (optional)
23. Install the front tires/wheels.
24. Lower the vehicle onto the ground and tighten the upper strut tower 1 0mm nuts S10518. Torque to 25 footpounds. (3 on each side)
25. RETORQUE ALL BOLTS AFTER 500 MILES.
floor jack, ball joint separator, jack stands, bench vise, and metric
hand tools.
2. Jack the vehicle in the center of the front cross member.
3. Support the vehicle by placing jack stands on the frame cross
member so that the front tire/wheels are off the ground.
4. Remove the front tires/wheels.
5. Disconnect the sway bar end links and remove the upper ball joint
cotter pin and nut.
6. Separate the upper ball joint from the spindle. (Using ball joint
separator or a suitable tool, be careful NOT to damage the ball joint
boot)
7. Remove upper s trut tower nuts h olding strut assembly to strut tower
(3) on each side of vehicle.
8. Remove the lower strut bolt from the lower control arm and remove
the strut assembly from the vehicle. (Note the direction of the bolt
for reinstallation)
9. Compress the coil spring on the strut assembly with a suitable coil
spring compressor so that the coil spring has about 3/8” play in the
strut and remove the upper strut isolator mount nut.
10. Remove the compressed coil spring assembly and dust boot from
the strut.
11. Install the supplied strut boot onto the lower factory stem cushion
washer. (optional)
12. Remove the coil spring isolator from the upper strut mounting plate.
13. Replace the upper strut mounting plate studs with the supplied
10mm longer studs S10762 with a bench vise and a deep well
socket. (3 on each side)
14. Install the supplied coil spring isolator M03272 to the upper strut
mounting plate.
15. Reinstall the compressed coil spring onto the strut assembly and reattach the upper strut mount plate using the stock hardware. See
diagram. Torque upper strut mounting plate nut to 18 foot-pounds.
INSTALLATION INSTRUCTIONS
FRONT
www.DaystarWeb.com
Tech Support Contact Info
Tech@DaystarWeb.com
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71
st
Avenue
Phoenix, AZ 85043
NUT
WASHER
CUSHION
MOUNTING
PLATE
M03272
CUSHION
WASHER
COIL
SPRING
M00337
BOOT
STRUT WITH
FACTORY
BOOT
Instruction Sheet Page 1 of 2 P10494
Rev 12
© 2005 Daystar Products International Inc
.
Page 2
www.DaystarWeb.com
Tech Support Contact Info
KT09102 1995.5-2004 Toyota Tacoma 2 ½” Lift Kit With 6 Lug
2WD/4WD
CAUTION: BEFORE BEGINNING INSTALLATION. READ INSTRUCTIONS CAREFULLY AND COMPLETELY.
1. Park vehicle on a level work area and set emergency brake. Block front tires and lift the rear of the vehicle until the wheels clear the ground
approximately 3”. Place jack stands under frame rail behind inner spring perch. Lower vehicle onto jack stands with axle supported by floor
jack.
2. Carefully remove upper and lower spring shackle mounting hardware and left and right shackle plates. Lower axle carefully until wheels touch
the ground.
3. Carefully remove the existing rubber and metal outer shell. The spring eyes have a rubber bushing that is molded into an outer shell. This
needs to be removed and it may take force to remove it. It is recommended that you have an experienced mechanic perform this operation.
4. Clean the I.D. of the spring eye and the frame with a wire brush or sand paper. Install the new bushings into the frame and the spring eye.
5. Install the new shackle onto the frame with the small opening first. Insert the 5” bolt and start the nut. Carefully raise the axle so that the large
opening of the shackle lines up with the spring eye. Insert the 6” bolt and tighten nuts 35 ft lbs.
6. Generously grease the Zerk fittings with Daystar Lubrathane Poly Lube or Teflon based grease. DO NOT USE OIL BASED GREASE!
7. Raise the vehicle and remove the jack stands. RE-TORQUE THE SHACKLE BOLTS AFTER 500 MILES.
8. Remove the rear rubber exhaust hanger and lower the exhaust bracket down 1 hole. Some trimming may be required. Install the supplied new
exhaust hanger. This is so that the exhaust won’t rub on the bottom of the rear leaf spring.
Tech@DaystarWeb.com
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71
Phoenix, AZ 85043
st
WARNING
This vehicle has been modified to enhance its per formance. The steering, braking
and handling of this vehicle will differ from standard passen ger cars an d truck s, This
vehicle handles differently from an ordinary vehicle in dri ving conditions which may
occur on streets, highways and off road. Avoid unnecessary abrupt maneuvers,
sudden stops, sharp turns and other driving conditions that could cause loss of
control, possibly leading to a roll over or other accident that could result in serious
injury or death to driver and passengers. If larger tires are installed the speed ometer
will read lower than the vehicles actual speed.
DRIVE WITH CARE, REDUCE SPEED AND WEAR SEAT BELTS AT ALL TIMES.
This kit should be installed by a professional mechanic
Avenue
Instruction Sheet Page 2 of 2 P10494
Rev 12
© 2005 Daystar Products International Inc
.
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