Daystar KT09119-1 User Manual

KT09102

Toyota Tacoma 2 1/2

Easy install front & rear shackle

4wd & 2wd 6 lug only

1995.5-2004

www.DaystarWeb.com

Tech Support Contact Info

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Phone: [phone]

Fax: [phone]

841 South 71

Phoenix, AZ 85043

st

Avenue

Instruction Sheet P10494-13
2008 Daystar Products International Inc.

1 of 3 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.

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.

Bill of Materials

TOOLS NEEDED

Part No. Description

1. Floor Jack

2. Jack stands

3. Wheel chocks

4. Set of metric tools from
10mm to 19mm

5. Hammer

M20282 Front spacer 2

S11057 Stud Extenders 6

P10495 Instructions 1
M03377 Frame bushing 4
M03245 Spring bushing 4
M03274 Exhaust Hanger 1

S10462 Shackle 2

S10233 18mm-2.5 x150mm bolt 2

S10231 18mm-2.5x 110mm bolt 2

S10204 18mm-2.5 nut 4

QTY

P10027 Grease Pack 2

Installation Steps

CAUTION: BEFORE BEGINNING INSTALLATION. READ INSTRUCTIONS CAREFULLY AND COM-

PLETELY.

15. 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.

16. Carefully remove upper and lower spring shackle mounting hardware and left and right shackle plates. Lower
axle carefully until wheels touch the ground.

17. 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.

18. 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.

19. 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.

20. Generously grease the Zerk fittings with Daystar Lubrathane Poly Lube or Teflon based grease. DO NOT USE
OIL BASED GREASE!

21. Raise the vehicle and remove the jack stands. RE-TORQUE THE SHACKLE BOLTS AFTER 500 MILES.

22. 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.

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.

This vehicle has been modified to enhance its performance. The steering, braking and handling of this vehicle will differ from standard 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 dr iving 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 driv er and passengers. If larger tires are instal led 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