Installation Instructions (PDF Format)
Contents
1. ESTABLISHED IN 1977 KC09134BK 2wd KC09135BK 4wd KC09137BK 2wd amp KC09138BK 4wd May 2013 amp Up Ram 3500 2 0 Leveling Kit 2014 amp Up Ram 2500 2 0 Leveling Kit GO EVERYWHERE WARRANTY LIKE Us SHARE US WATCHUS FOLLOW US www Daystarweb com _ Instruction Sheet P21230 Tech Support Contact Info Sa hi al Tech DaystarWeb com Phone 623 907 0081 Sare Gaia Fax 623 907 0088 oon a e Revised by PH 841 South 71 Avenue 7 Introduction Ki SveveEyesrr is your number one source for Made In The USA i quality Comfort Ride leveling kits Now backed root sod ep Asaris With our exclusive Go Everywhere Lifetime Lim ited Warranty see terms at Daystarweb com To assure your safety and prop er installation of this product take a moment to read all instructions and Prod uct Safety Information before trying to install your Daystar product Current OEM suspension design is complex meaning safe and proper installation requires understanding OEM service techniques for disassembly and assembly of the components indicated together with the instructions and warnings set out below and in the OEM service manual and your owner s manual Day star strongly recommends seeking advice from or having this product in stalled by a professional mechanic who can inspect your suspension confirm compatibility with your tire and wheel choice and if needed reset alignment to optimize your steering and the featur2. proceed with the installation Please call Daystar Products 800 595 7659 and we will send you the missing of damaged components free of charge Caution Vehicle front end must be raised to install leveling kit Using a hydraulic chassis lift will greatly ease installation If another jack is used assure vehicle is level on a firm sur face in park 1st gear rear wheels blocked and jack stands in place to support vehicle in case jack or vehicle shifts 1 Longer shocks are required Daystar Scorpion shocks part KC09136 are specifically designed to be used with the level ing spacers If you are not using the specified Daystar shocks heed the following warning Warning Dodge designed the shock to be the limiting component of the front suspension This feature was retained with the Daystar leveling kit Additional shock travel under certain conditions may allow the coil spring to become dis lodged 2 Chock the rear wheels and set the parking brake so the truck will not move during the lifting process 3 With the truck on a hard level surface use a floor or bumper jack to raise the front of the vehicle 4 Securely support the truck with two 2 frame jacks Tip You will want to have the vehicle high enough off the ground to allow the front suspension to drop out completely 5 Remove the wheels from the front driver and passenger sides of the truck Tools 23mm deep socket 1 2 ratchet 6 With a floor jack support
3. ations herein Daystar warrants to the initial retail pur chaser that your Comfort Ride or Budget Boost leveling kit shall be free of defects in material and workmanship for so long as it is properly installed on a single vehicle owned by the initial retail Daystar purchaser What is Not Covered Your Vehicle amp Parts Not Daystar s GoEvery where Your Daystar Limited Warranty does not cover a damage to your vehicle vehicle systems ex electronic stability control other products components or property not manufactured by Daystar to our exclusive GoEverywhere stand ards b customer choice of vehicle configuration tire and wheel combina tions contrary to Daystar recommendations warnings or applicable laws C Acts of God weather corrosion accidents theft vandalism negligent misuse or intentional damage other exclusions under your OEM Limited War ranty Remedy Limited to Repair Replacement Get back on your favorite trail fast The exclusive remedy provided hereunder shall upon Daystar s inspec tion and option be either repair or replacement of the Comfort Ride or Budget Boost leveling kit or parts covered under this Limited Warranty Call us and we will get you back wheelin 623 907 0081 All labor removal shipping and installation costs are customer s responsibility Other Exclusions Limitation of Damages Your Rights Under State Law Stuff Lawyers Say At Daystar we aren t big fa
4. es of your Daystar Comfort Ride kit We are here to help if you have remaining technical questions after reading these instructions Contact us toll free at 800 595 7659 Product Safety Information Throughout these instructions important safety information is generally pre ceded by one of three signal words indicating the relative risk of injury The signal words mean WARNING A hazardous situation which if not avoided could result in death or serious injury You can be Killed or Seriously Hurt if you don t fol low instructions CAUTION A hazardous situation which if not avoided could result in minor or moderate injury You can be moderately HURT and also may suffer property damage if you don t follow instructions NOTICE Careful attention is required to this instruction or operation but does generally not relate to personal injury Damage to your product or other property may result if you don t follow instructions WARNING Familiarize yourself with all vehicle manufactures and Daystar warnings instructions and limited warranties before driving your modified suspension vehicle Also be aware many states coun tries have laws governing on road vehicle heights and modifica tions You are responsible for assuring the safety and legality of your vehicle A summary of current state vehicle laws is available at Www sema org What is Covered Real Life Use Off Road amp On Subject to the terms exclusions and limit
5. is process 9 Loosen do not remove the radius arm frame bolt on both the driver and passenger sides Tools 27mm socket 1 2 ratchet XY Radius Arm Bolt 10 Lower the floor jack to relieve pressure on the coil spring Notice Do not overextend the brake line 11 Once the tension is released remove the coil spring Tip Take notice and mark the top of the spring Caution Coil spring maybe compressed even with axle suspension at full travel Use spring compressor during re moval Keeping hands and other body parts clear at all times 12 Remove the factory upper spring isolator Tip The Daystar leveling spacer s stud will locate using the same hole as the barb on the factory isolator 13 Discard the factory spring isolator It will not and cannot be used with the Daystar leveling spacer 6 14 Install the Daystar leveling spacer Torque nut to 30ft lbs Do not over tighten Parts Leveling spacer 5 16 flat washer amp 5 16 nylock nut Tools 1 4 ratchet 1 2 deep socket 15 Remove the factory bump stop Discard the factory bump stop as it will no longer be used
6. n and 8mm Open End Wrench that they remain clear of springs or other obstructions 4 Wheel Chocks 29 Install Warning to Driver decal on the vehicle s sun 4 visor or dash The decal must be placed in a conspicuous Coil Spring Compressor location Anyone that operates the vehicle must be made Bill of Materials aware of the changes made 30 After 25 miles of driving re torque the lug nuts to 120 ft lbs 31 After 500 miles of driving re torque all of the hardware M21161 a Leveling associated with the leveling spacer installation to factory Pose specifications Repeat torqueing procedure as required 2 M02378 BK 01 Front Extended ae NOON Bump Stops Daystar Lifetime GoEverywhere Limited Warranty S10114 5 16 Nylock Nut Your Daystar Comfort Ride or Budget Boost leveling kit is covered by the 2 S10829 5 16 Flat Washer following Go Everywhere Lifetime Limited Warranty provided exclusively 2 510829 3 16 Flat Washer by Daystar Products International Inc 841 South 71st Ave Phoenix AZ P21138 Daystar Decal 85043 Daystar P10474 Warning Decal 3 Installation Instructions Warning Always work with appropriate personal safety gear including safety glasses gloves and hearing protection if using air powered tools Begin by inspecting the components amp hardware for damage Then compare components amp hardware to the bill of materials for completeness If anything is missing damaged do not
7. ns of lawyers even ours Still he says our Lim ited Warranty has to include this stuff In consideration of the purchase price paid neither Daystar nor any independent Daystar distributor or repair per son are responsible for any time loss loss of vehicle use rental costs transpor tation labor or for any incidental consequential punitive or other damages you may have or incur in connection with any part or product purchased No Daystar employee or independent distributor is authorized to make any state ment or representation altering the terms of Daystar s GoEverywhere Lifetime Limited Warranty Your exclusive remedy hereunder for covered parts is repair replacement as described above This Limited Warranty gives you specific rights You may also have other rights that vary from state to state For example some states do not allow limitations of how long an implied warranty lasts and or do not allow the exclusion or limitation of incidental or consequen tial damages so the limitations and exclusions herein may not apply to you All other warranties are hereby disclaimed except to the extent prohibited by applicable law in which case any implied warranty of merchantability fitness for a particular purpose or other implied warranty are limited to a period of four 4 years from date of initial retail purchase Daystar reserves the rights to a require invoice or other proof of purchase b make future revisions to these pr
8. oducts and Limited Warranty without prior notice or obligation to upgrade your Daystar product Daystar Products International Inc 9 15 13 All rights reserved 11 20 Repeat the leveling spacer bump stop and shock installa Tools Needed tion procedure on the passenger side 21 Reinstall the sway bar end link that was disconnected in step 7 Tools 21mm box end wrench 10mm open end wrench 22 Torque lower shock bolts amp sway bar nuts to 65ft lbs Then double check the installation Tip Upper shock nuts are properly torqued when the bushings have a slight bulge 23 Reinstall driver and passenger tires and wheels 23mm Deep Well Socket 24 Remove jack stands and lower the truck back on the Pi Socket ground Remove all jacks and jack stands from under ve hicle 1 2 Ratchet 25 Torque the lug nuts to 120 ft lbs using an X pattern 26 Torque the rear radius arm bolts to 220 ft lbs 1 4 Ratchet 27 Center the steering wheel R re Caution Have an alignment professional check and ad ie ee he enor pean just the alignment to factory specifications 21mm Ratcheting Box End Wrench 28 With the vehicle on the ground cycle the steering wheel side to side and inspect suspension components brake 18mm Ratcheting Box End Wrench lines and tires to ensure there are not any clearance issues 10mm Open End Wrench Jounce the suspension to assure front suspension operates freely brake lines retain proper slack at full extensio
9. the Driver side of the front axle and compress it slightly Warning Make sure that during the compression process the frame does not come off the frame jacks Tools Floor jack 18 With the floor jack raise the axle until the spring touches the Daystar spacer Tip Make sure the end of the coil spring comes into contact with the coil stop cast into the Daystar Leveling Spacer The orientation of the Driver and Passenger side coil spring stops are different The Driver s side coil stop faces toward the tire while the Passenger s side coil stop faces the shock Install Daystar Scorpion shocks Tip Steel tube sleeve will need to be installed along with the lower hourglass shock grommet Tools Upper nut 19mm ratcheting box end wrench 8mm open end wrench Lower bolt 21mm socket 1 2 ratchet 16 Install the Daystar extended bump stop Parts Extended bump stop Note It takes some effort to get the bump stop to seat Some WD 40 will help with the process 7 Remove the factory shock absorber Tools Lower bolt 21mm socket amp 1 2 ratchet Upper nut 18mm ratcheting box end wrench 8mm open end 8 Disconnect sway bar end link at the axle Tools 21mm ratcheting box end wrench 10mm open end wrench 17 Reinstall the factory spring Tip With the leveling spacer in place it may be required to use a spring compressor to reinstall the coil spring Make sure the brake lines is not overextended during th
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