Daystar KT09119BK User Manual
www.DaystarWeb.com
Instruction Sheet P10720
-01
Figure 1
.
S10321 Cab
Positions 2 & 3
Position 1
KT04506 1995.5-2004 Toyota Tacoma 1” Body Lift Kit
Cab Installation
Bill of Materials
Part # Description Qty
M02850
M03551
M02787
M02845
M03550
S10126
S10128
S10138
S10203
S10114
Body Mount 2
Body Mount 2
Body Mount 4
Body Mount 4
Bed Mount 2
Washer 2 1/2" 8
Washer 1 1/4" 6
Washer 1 1/2" 6
Nut 7/16 6
Nut 5/16" 2
S10773 Bed Bolt 12 x 50mm 6
S10789
S10200
S10777
Bolt 7/16 x 4 1/2" 4
Bolt 7/16 x 5” 2
Bolt 5/16 x 2" 2
S10129 Steel Tubing 3 3/8" 4
S10012 Steel Tubing 2 1/4" 2
S10775 Bed Tubing Spacer 6
S10321
S10776
Cab Bracket 4
Steering Coupler 1
S10789 Bolt
OE Washer
Cab Floor
S10126 Washer
M02845 Cab Mount
Bracket
M02787 Cab Mount
S10129 Tubing
S10126 Washer
S10203 Nut
1. RADIATOR FAN SHROUD: Only raise body
high enough to remove and replace body
mounts. Always watch the fan shroud for
sufficient clearance when raising the body.
2. Remove the 12mm bolts and nuts from the upper steering coupler on the rack and pinion
noting the position of the steering column. Note: do not let the steering column turn, keep
the column and rack aligned to its original position, mark if necessary. See figure 2.
3. Loosen body mount bolts on the driver’s side of vehicle and remove bolts from opposite
side for positions 1,2 and 3, see Figure 1. Place a 2x4 between the jack and body to
spread out load.
4. Raise the body on the driver’s side just far enough to remove mounts. T emporarily prop
up the cab between cab and the frame with a wooden 2x4 or spacer. (This is to avoid
cab from falling while working on body mounts.) The bolts on the opposite side will help
ensure that the body does not shift. Make sure cab doesn’t contact bed when lifting.
5. Remove factory mounts one at a time.
6. Install the new S10321 steel bracket, polyurethane body mounts, and steel sleeves in
positions 1, 2 and 3. Refer to the diagrams for positions. NOTE: On 2001 and newer
models you will need to invert the #2 position bushings so that the M02787 is on top.
7. Install the supplied aluminum steering coupler with the round bosses pointing down.
Note: you may have to loosen the pinch bolt at the top of the steering coupler so that it
will slide up enough to install the steering coupler. See figure 2.
8. Lower the driver’s side and START the new bolts into the new mounts. Reconnect the
steering coupler with the supplied 5/16” bolts from the top and nuts. DO NOT TIGHTEN!
9. Now remove bolts from passenger side of vehicle and repeat steps 3 through 6.
10. Tighten the steering coupler bolts and nuts to 35ft lbs also tighten the upper steering bolt
to 35ft lbs.
Tech Support Contact Info
Tech@DaystarWeb.com
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71st Avenue
Phoenix, AZ 85043
S10200 Bolt
S10138 Washer
Radiator Support
S10138 Washer
M03551 Cab Mount
S10012 Tubing
Frame
M02850 Cab Mount
S10138 Washer
S10203 Nut
© 2004 Daystar Products International Inc.
www.DaystarWeb.com
P10720 REV01
W
ARNING
Figure 2.
OE Upper
S10776 Aluminum
OE Lower Steering
Insert rectangula
r
support.
S10775 Bed
Figure 3.
Tech Support Contact Info
KT04506 1995.5-2004 Toyota Tacoma 1” Body Lift Kit
Tech@DaystarWeb.com
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71st Avenue
Phoenix, AZ 85043
Bed Installation
1. Loosen the 6 bed mount bolts. Remove 3 bolts from one side. Place a 2x4 between the jack and bed to spread out load.
2. Raise the bed on the side you have removed the bolts from just far enough to install the rectangular steel tube bed spacers and start the new
supplied 12mm bolts. The bolts on the opposite side will help ensure that the bed does not shift. See figure 3.
3. Install the rectangular polyurethane bed spacer on to the bed, sliding the clip into the bed rail support near the tire. See figure 4.
4. Remove bolts from other side of bed and repeat steps 2 and 3.
5. Once all new mounts are in place, align the bed with the cab. Re-torque all bolts to 60ft lbs, DO NOT over tighten bolts.
6. Before starting engine, check fan for clearance from fan shroud and make sure all lines and wires are free and clear.
Steering Coupler
to column.
Steering Coupler
Coupler on Rack &
Pinion
polyurethane bed
spacer in wheel
well onto bed
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 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 speedometer 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.
OE Bed Nut
Bed Support
Tubing Spacer
S10128 Washer
S10773 Bolt
Frame Rail
Figure 4.
© 2004 Daystar Products International Inc.
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