Daystar KU70086BK User Manual

Step(s), Fig 2

1997-2004 Adjustable Length Jeep TJ Control Arms
KU70083 2”Adjustable Length Jeep TJ Control Arms (Front/Upper)
KU70085 2”Adjustable Length Jeep TJ Control Arms (Rear/Upper)
KU70084 2.5”Adjustable Length Jeep TJ Control Arms (Complete Lower)

Instruction Sheet – P10829-01

www.DaystarWeb.com

Tech Support:

[email protected]

Phone: 623.907.0081 Fax: 623.907.0088

841 South 71

Avenue, Phoenix, AZ 85043

Bill of Materials

Part #

Description

Qty

Front Upper Control Arm Extension

0-2

Rear Upper Control Arm Extension

0-2

Fr/Re Lower Control Arm Extension

0-4

Poly-Flex

Assembly

2-8

Fig 1.

Step(s)

Inspect the contents of the kit and read the entire instructions before proceeding.

Using a press or a vise; install the components into each of the Poly-Flex tubes in

the order shown in (Fig. 1).[For more detail, see the following pages with
component descriptions and drawings]

Thread a jam nut onto a threaded Poly-Flex assembly and thread the Poly-Flex

assembly into the end of the control arm.

Chock wheels on opposite side of vehicle that you are working on. Put one end of

the vehicle on jack stands and a floor jack under the axle, support the axle with the
jack. Lift just enough to get the stress off of the original control arm to remove it.
(Daystar recommends that only one arm at a time should be removed and that the
lower control arms should be pulled first.)

Note the hole center to hole center length of the original control arm. (Fig. 2)

Make sure that the hole spacing on the Poly-Flex assemblies match the existing

factory control arms. If the Jeep is lifted, a custom length will have to be adjusted,
check (Chart1) on the following page for hole center to hole center length.

Install each control arm. Note: Use the ½” washers in place of the cam bolt for the lower front

control arms. Also, before installing the rear upper arm, the carriage bolt hole on the axle must be
drilled.

Tighten upper arm bolts to 60 Ft-Lb and lower to 90 Ft-lb. Tighten jam nuts and check all fasteners

after 100 miles. Reattach the emergency brake cables to the control arms using zip-ties.

Finally with Poly-Lube in a grease gun, inject a small amount of Poly-Lube into each of the Zerk

(grease) fittings.

NOTE: Daystar recommends a transfer case drop [P/N KJ01008] on lifted vehicles. A wheel alignment
should be done after installation. Check all under carriage bolts and nuts and Jam Nut after offroading.

Tools required

Description: Qty.

Press or Vice

Floor Jack

Retaining Clip pliers

Jack Stand(s)

Drill and 7/16 bit

Grease

Fig 2