Daystar KJ60013 - Manual

Shackle Installation Instructions
DO NOT COMBINE WITH ANY OTHER SUSPENSION KIT
CAUTION: BEFORE BEGINNING INSTALLATION, READ ALL INSTRUCTIONS CAREFULLY
AND COMPLETELY.
1. Park vehicle on level work area and set emergency brake. Block tires opposite of the ones being lifted. Lift
one end of the vehicle using the floor jack until the wheels clear the ground about 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, left, and right shackle plates. Lower
axle carefully until the wheels touch the ground. Make sure that the brake line and the vent line is not over
stretched.
3. If installing a Greaseable Super Shackle, remove the spring eye bushing/steel sleeve assembly from the
spring eyes. See figure 1. Some of the frame shackle bushings need to be burnt out leaving the steel outer
shell in the frame. Do not damage the outer shell. Clean with a wire brush or sandpaper.
4. Install the corresponding bushings into the spring eye and into the frame and lubricate with silicon or Teflon
lubricant. Daystar Lubrethane Poly Lube is recommended. See figure 2 and 3. Install the steel sleeves if
provided.
5. Install the shackles onto the frame. Shackles with the off-center tube, install the long end up towards the
frame and the short end down goes towards the spring. The center support is designed to eliminate shackle
flex. (When going to longer shackles, you are raising the center of gravity, which tends to make the vehicle
over-steer. By welding a center tube in the shackle, it eliminates the sway and spring roll improving the
handling characteristics and side flex for off road purposes.)
6. Install the upper bolts. Tighten the nuts so the shackles swing freely. DO NOT OVER-TIGHTEN THE NUTS
OR THE SHACKE will bind causing a stiff ride and limiting suspension travel.
7. Using the floor jack raise the rear axle until the spring eye aligns with the shackle. Insert the bolt. Tighten the
nut. DO NOT OVER-TIGHTEN BOLTS AND NUTS! Damage to shackle could result!
(Note: Daystar includes a Nylock nut that limits the nut from coming loose.)
8. You will not need to worry about driveline vibration due to changing pinion (driveline) angle. You are working
on a fulcrum so as you lift, you pivot the pumpkin-differential and pinion (driveline) at the same time. If you
have a drive-shaft vibration first check the universal joints for wear. If the universal joints are good, on taller
lifts you might need to install degree shims between the axle housing and the spring to change your pinion
(driveline) angle. On many vehicles you can drop the transfer case down from the frame which will also
change the pinion (driveline) angle.
9. On greaseable shackles, grease the shackle bolts with silicon or Teflon lubricant. Daystar Lubrethane Poly
Lube is recommended after installation.
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Tech Support Contact Info
[email protected]
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71 st Avenue
Phoenix, AZ 85043
Typical Bill Of Material
Greaseable Shackles Non Greaseable Shackles
Description Qty. Description Qty.
Shackles 2 Shackles 2
Bolts 4 Bolts 4
Nuts 4 Nuts 4
Bushings 8
Steel Sleeves 4
NOTE: Not all greaseable kits
come with steel sleeves
WARNING
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.
Do not combine with any other suspension kit.
This kit should be installed by a professional mechanic.
Fig. 3
Fig. 2
Fig. 1
Instruction Sheet P10509-04
© 2008 Daystar Products International Inc.