Daystar KT09119BK User Manual
Cab installation
www.DaystarWeb.com
Tech Support Contact Info
Phone: 623.907.0081
Fax: 623.907.0088
841 South 71
st
Avenue
Phoenix, AZ 85043
Bill of Materials
Part #
Description
Qty
M02850
Body Mount
2
M03551
Body Mount
2
M02787
Body Mount
4
M02845
Body Mount
4
M03550
Bed Mount
2
S10126
Washer 2 1/2"
8
S10128
Washer 1 1/4"
6
S10138
Washer 1 1/2"
6
S10203
Nut 7/16
6
S10114
Nut 5/16"
2
S10773
Bed Bolt 12 x 50mm
6
S10789
Bolt 7/16 x 4 1/2"
4
S10200
Bolt 7/16 x 5”
2
S10777
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
Cab Bracket
4
S10776
Steering Coupler
1
KT04506 1995.5 -2004 Toyota Tacoma 1” Body Lift Kit
Cab Installation
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. Temporarily 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.
Instruction Sheet P10720-01
© 2004 Daystar Products International Inc.
Figure 1.
S10789 Bolt
Cab Floor
S10126 Washer
M02845 Cab Mount
S10321 Cab
Bracket
M02787 Cab Mount
S10129 Tubing
S10126 Washer
S10203 Nut
Positions 2 & 3
OE Washer
Position 1
S10200 Bolt
Radiator Support
S10138 Washer
S10138 Washer
M03551 Cab Mount
Frame
M02850 Cab Mount
S10138 Washer
S10203 Nut
S10012 Tubing