Daystar KG09121 - Manual

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Instruction Form #P20516-01
Daystar Products International
841 S. 71 st Ave.
Phoenix, AZ 85043
800-595-7659 toll-free
623-907-0081 local
623-907-0088 fax
www.daystarweb.com
Rear Block Kit Instructions
Thank You for Choosing Daystar
Daystar recommends a certified technician install this system . In addition to these instructions ,
professional knowledge of disassemble/reassembly procedures as well as post instruction checks must
be known. Attempts to install this system without this knowledge and expertise may jeopardize the
integrity and/or operating of the vehicle.
Please read all the instructions before beginning the installation. Be sure you have all the needed parts
and understand where they go. If anything is missing, do not proceed with the installation, Call Daystar
Products to obtain needed items.
Installation Procedure
1. Place the vehicle on a flat, level surface and set the parking brake. Raise the rear of vehicle with a
floor jack positioned under the rear axle. Place jack stands under the frame rails, a few inches in front of
the rear springs’ front hangers. Ease the jack down until the frame is resting on the stands. Keep a slight
load on the jack. Chock front tires.
2.
Remove the tires. Unbolt the shock absorbers from the axle.
3. Remove the spring-to-axle U-bolts. Use the jack to carefully lower the axle down enough for block
installation. Do not overextend the brake and axle vent hoses, or any wiring.
4. When a vehicle is factory equipped with lift blocks, generally the factory blocks have an arm that acts
as a contact point for the compression travel stop. The supplied blocks should be positioned
UNDERNEATH the factory blocks.
5. Inspect the block-to-spring perch contact area. The spring perch must be perfectly flat in order for the
blocks to seat properly. If the perches are not perfectly flat, they must be repaired or replaced before
continuing.
6. Be sure the spring perches are clean and free of debris. Inspect the supplied lift blocks; if there is a
taper present in the block, position the block so that the “tall” end of the taper faces rearward and the
“short” end faces forward. Be sure that the spring centering pin(s) are seated properly in the hole(s) of
the blocks, and that the block pin seats properly in the spring perch. Position the spring-to-axle U-bolts
and install the furnished U-bolt flat washers using the stock U-bolt retaining plate. Evenly tighten the U-
bolts using an “X” pattern.
½” U-bolts…….75-80 ft-lbs.
9/16” U-bolts….85-90 ft-lbs.
5/8” U-bolts……90-110 ft-lbs.
7. Install the new shock absorbers or reconnect old shocks (if applicable). Reinstall tires and torque to
factory specifications. Lower the vehicle to the floor.