Daystar KJ04002BK - Manual

KJ04002 & KJ04004 80-86 CJ-5, CJ-7, CJ-8 Body Mount Installation Instructions
Before beginning read all instructions and check Bill of Materials
1. PLASTIC 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. Loosen body mount bolts on one side of vehicle and remove bolts from opposite side for positions 1,5 and 6 (ref.
Fig.1) and positions 2, 3 and 4. Use a long extension to remove mounts next to gas tank. Place 2x4 between jack
and body to spread out load and jack up body on the side you have removed the bolts from just far enough to
remove mounts. The bolts on the opposite side will help ensure that the body does not shift. CAUTION: Open
Hood while jacking up the body to make sure that the fan doesn’t hit the shroud. Also, watch that hoses and wires
are not stretched. When lifting the side of the vehicle that the fuel filler is on keep a close eye not to stretch, tear
or pull too far on the hose connection.
3. Remove factory mounts one at a time.
4. Jack up the body using a 2x4 under one side of the body for support just high enough to insert new body
spacers. If the steel collar on new mounts will not insert in frame holes, you may have to file out frame mount hole
slightly to install spacer. Repeat on opposite side.
5. Now remove bolts from other side of vehicle and repeat instructions 3 through 6.
6. Once all new mounts are in place, you may re-torque all bolts to factory specs. Do not over tighten bolts.
7. Before starting engine, check fan for clearance of all lines and wires to make sure they are free and clear.
www.DaystarWeb.com
Tech Support Contact Info
[email protected]
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71 st Avenue
Phoenix, AZ 85043
Bill of Materials
Part No. Description KJ04002 KJ04004
M02284 Bushing 1 1
M02285 Bushing 1 1
M02287 Bushing 8 10
M02288 Bushing 10 12
M02289 Bushing 2 2
S10125 Washer ½” 11 13
CJ-8 Scrambler
Only