KT09104
Toyota Tundra 2 1/2
Easy Front Install & Rear Add-a-Leaf
4wd & 2wd 6 lug only
1995.5-2006
www.DaystarWeb.com
Tech Support Contact Info
Tech@DaystarWeb.com
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71
Phoenix, AZ 85043
st
Avenue
Instruction Sheet P10505-10
2008 Daystar Products International Inc.
1 of 4 pages
1. Read all instructions and check bill of materials and tools before beginning.
2. Disconnect the negative battery cable.
3. Place the vehicle on a clean and level surface. Set the parking brake and
place wheel chocks behind the rear wheels. Jack up the front of the vehicle
by the frame with a floor jack and support vehicle at the frame rails with approved jack stands. NEVER WORK UNDER AN UNSUPPORTED VE-
HICLE.
4. Disconnect the ABS and brake lines from the upper a-arm and spindle
( 10mm and 12mm bolts.
5. Disconnect the sway bar on both side at the spindle. ( 17mm bolt. )
Installation Steps
6. Remove the upper strut nuts.( 14mm nuts ) You will need to reuse them later.
7. Remove upper ball joint nut ( 19mm nut ) and separate the ball joint from the
spindle by hitting the side of the spindle. DO NOT use a ball joint separator
tool it can damage the ball joint boot.
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 result in the proper amount of lift out at the wheel.
Installation Steps
8. Remove the lower strut bolt and nut ( 19mm) .
9. Remove the strut from the vehicle.
10. Install the stud extenders and spacer on the top of the strut plate.
11. Reinstall the strut into the vehicle and tighten the upper strut nuts. You will have
to push up on the upper a-arm to get the strut back in.
12. Reinstall the suspension working in reverse order.
13. Recheck all bolts after 500 miles.
14. Daystar Recommends that you have your wheel alignment checked.
TOOLS NEEDED
1. Floor Jack
2. Jack stands
3. Wheel chocks
4. Set of metric tools from
10mm to 19mm
5. Hammer
Part No. Description
S10535 Add-A-Leafs 2
S10533 Bolt ( Leaf spring) 2
S10534 Nut ( Leaf spring) 2
Bill of Materials
Part No. Description Qty
M20282 Spacer 2
S11057 Stud ext 6
P10495 Instructions
QTY
Installation Steps Rear
15. Lift the rear of vehicle and place jack stands on frame so that the rear tires almost touch the ground
16. Remove the rear tires and wheels.
17. Disconnect the rear shocks at the axle.
18. Support the rear axle with the floor jack and loosen all four U-bolts. Remove two U-bolts and clamp from one
side.
19. Lower the axle away from the spring so that the drum is clear of the leaf Spring. Bend the spring clamps down
and away from the spring. Remove the plastic clips from the spring clamps.
20. With the appropriate clamps, clamp the spring together and remove the bolt securing the springs together; you
may have to use Vise-Grips to hold the head of the bolt.
21. Carefully remove the clamps and note the position of the springs.
22. Sandwich the add-a-leaf between the four stock springs, the springs should stack up shortest to longest with the
longest on top. Install the supplied bolt from the bottom up and tighten to 45 foot pounds. (You will have to use
C-Clamps to compress the springs together.)
23. Raise the rear axle onto the spring assembly; make sure that the spring bolt head seats into the axle pad. Cut off
the excess thread 1/8” above the nut so that the stock bump stop will fit flush with the top spring when bolted
together.
24. Install the U-bolts and clamps, just starting the nuts.
25. Repeat steps 4 thru 8 for the other side of the axle.
26. Tighten the U-bolt nuts evenly to 105 foot pounds so that you have the same thread showing on all U-bolts.
27. Bend the spring clips over the new spring bundle. You may have to use a heavy hammer to do this correctly;
the spring clips should be tight.
28. Reconnect the shocks to the rear axle.
29. Install the rear tires and wheels.
30. Retighten the U-bolt nuts after 500 miles.
This vehicle has been modified to enhance its performance. The steering, braki ng and handling of this vehicle will differ from standar d passenger cars and trucks, This vehicle handles differently from an ordinary vehicle in driving conditions which may occur on streets, highways and
off road. Avoid unnecessary abrupt maneuvers, sudden stops, sharp turns and other driving conditions that could caus e loss of control, possibl y
leading to a roll over or other accident that could result in serious inj ury or death to driver and passengers. If larger tires are installed the speedometer will read lower than the vehicles actual speed.
DRIVE WITH CARE, REDUCE SPEED AND WEAR SEAT BELTS AT ALL TIMES.
Do not combine with any other suspension kit.
This kit should be installed by a professional mechanic.
WARNING
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