tactical lift kit · 2020. 6. 22. · tactical # 4004101 toyota tacoma toll free # 800.595.7659...
TRANSCRIPT
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
841 S 71st Ave · Phoenix AZ 85043
800-595-7659 · 623-907-0081
Kit 4004101
16 to Current Toyota Tacoma 4” Tactical Lift Kit
Installation Instructions
DO NOT INSTALL THIS KIT ON ANY VEHICLE
OTHER THAN THE ONE FOR WHICH IT IS
SPECIFIED.
If anytime during the installation you en- counter something different from what is outlined in the instructions, call technical support at (800) 595-7659.
PRE-INSTALLATION PREPARATION
1. Read all warnings and instructions
2. Locate tools needed: Welder or access to a professional welding
shop.
Die grinder or similar tool capable of cutting metal.
3. Verify all parts have been received in this kit by comparing with this parts list:
2 Front Strut Spacer
4 Lift Block, 3”x2” Round
8 Lift Block, 2”x2” Round
4 Bed Block, 2” x 2” x 2” Square
1 Bracket (front bumper, dvr)
1 Bracket (front bumper, psg)
1 Bracket (rear bumper, dvr, top)
1 Bracket (rear bumper, dvr, bottom)
1 Bracket (rear bumper, psg, top)
1 Bracket (rear bumper, psg, bottom)
1 Bracket (rear bumper, middle)
2 Plate, Radiator Block Off
1 Steering Extension
1 Extension, 1” x 6” Rubber Hose
1 Extension, 1/4” x 6” Rubber Hose
1 Extension, 5/8” x 6” Rubber Hose
1 Bolt Pack
1 Hardware Pack
1 Bag Kit
3 Thread Lock
Decal/Warning Labels
IMPORTANT
If parts are missing from kit, contact seller with:
Name of purchase location Bar Code on side of box Date above bar code Date inside box cover Inspector # from inside box cover
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
4. Take Down Measurements:
a. Distance between rear bumper and bed
Driver Side:
Passenger Side
b. Distance between cab and bed
Driver Side:
Passenger Side
5. Identify Fasteners to Reuse and/or Replace
When re-assembling the vehicle it is recommended by the vehicle manufacturer that certain fasteners are replaced in order to maintain proper retention characteristics.
Adhere to recommendations when replacement fasteners, retainers and keepers as called out in the factory service manual.
6. Prepare Vehicle for Install
a. Park vehicle on a clean, dry, flat, level surface and block tires so vehicle cannot roll in either direction.
7. Engine Compartment
a. Disconnect both battery cables. Disconnect negative cable first, then positive cable.
8. Inside Cab
a. Airbag Fuse
NOTE
The location of the airbag fuse may vary; check the owner's manual.
1. Remove fuse cover. 2. Remove airbag fuse.
9. Front Bumper
a. Remove wiring harness from fog lights, if equipped.
b. Remove two pop-up clips, two bolts, and grille from core support.
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IMPORTANT
This system may not include all replacement hardware as recommended by the factory service manual. Obtain additional replacement hardware prior to installation of this system to meet the re- quirements of the factory service manual.
Positive Cable (Red)
Negative Cable (Black)
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
c. Remove seven pop-up clips from front bumper.
d. Remove two pop-up clips from fender wells
e. Remove six screws and front bumper fascia from vehicle.
IMPORTANT
Use caution when removing front bumper fascia from vehicle. Carefully pull outward from fender on the sides of front bumper cover to loosen.
f. Remove six nuts and front bumper from vehicle.
g. Remove six nuts and two front bumper brackets Engine Compartment from frame rails.
10. Automatic Transmission Cooler: (if equipped)
a. Remove four bolts and allow automatic transmission cooler to hang loose from core support.
b. Remove two bolt and automatic transmission cooler lines from lower core support.
c. 6 cyl models: Loosen airbox clamp, two clips
and remove airbox cover from engine.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
d. 6 cyl models: AC Line.
1. Remove bolt and AC line bracket from body.
2. Remove two nuts, clamp, and rubber isolator
from AC line and bracket.
e. 6 cyl models: Remove power steering reservoir, three bolts and bracket from fender. DO NOT disconnect power steering lines.
f. 4 cyl models: Loosen two engine intake clamps and remove engine intake hose.
g. 4 cyl models: Remove bolt from passenger side AC line bracket.
h. 4 cyl models: Remove nut and AC line from passenger side AC line bracket.
i. 4 cyl models: Remove lower AC line from two clips and passenger side body.
j. Remove vent tubes from driver side body bracket.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
k. Remove heater hoses from clip on backside of engine.
l. Remove wire harness clip from firewall and bracket.
m. Remove ABS wire harnesses from driver and passenger side.
n. Remove wire harness and two clips from alternator bracket and driver side body bracket.
11. Radiator
a. Remove nine pop-up clips and radiator cover
from core support.
b. Remove four bolts and radiator from core support. Allow radiator to hand on core support by tabs.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
NOTE
Lower the radiator onto the frame prior to the lifting procedures.
WARNING!
Accidental deployment of the air bag can result in serious personal injury or death. To avoid ac- cidental deployment during installation of the lift kit, the Supplemental Restraint System (SRS, or airbag) must remain deactivated. Do not allow anyone near the airbag during installation. Re- fer to the factory service manual or owner’s manual for the recommended procedure to disa- ble the SRS. After kit installation, the SRS must be reactivated before driving the vehicle.
c. Strap steering wheel to prevent accidental movement.
d. Mark upper steering shaft in relation to coupler and lower steering shaft.
e. Remove coupler bolts, slide coupler up onto upper steering shaft and disconnect steering shaft.
f. Slide coupler down and off upper steering shaft.
g. Position steering coupler onto lower steering shaft.
12. Inside of Vehicle
a. Manual transmission
1. Remove center console and shifter console
interior panes.
2. Remove shift lever from vehicle.
2. Front interior trim panels
a. Remove driver and passenger door sill plates.
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If the following step is not performed, the airbag clock-spring could be damaged. Do not turn the steering wheel while the steering shaft is discon- nected.
CAUTION
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
b. Remove dead pedal.
c. Remove driver and passenger kick panels.
d. Pull driver and passenger carpet back from corner and expose body mount bolt access cover.
e. Remove driver and passenger body mount
bolt access cover.
3. Extended cab models: Rear interior trim panels
a. Fold down rear seats.
b. Open floor storage tray and remove jack.
c. Remove pop-up clips and storage tray from vehicle.
d. Pull carpet up to expose diver and passenger body mount access plates.
e. Remove four bolts, and driver and passenger
body mount access plates.
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NOTE
Procedures may vary depending on cab model for access to rear body mount bolt access co- vers.
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
f. Remove driver and passenger body mount bolt access covers.
4. Crew cab models: Rear interior trim panels
a. Remove three headrests from seatbacks and
fold seatbacks down.
b. Remove three bolts and pop-clips from driver
side rear panel and cab.
c. Remove bolt and pop-clips from passenger side rear panel and cab.
d. Remove driver and passenger body mount bolt access covers.
13. Underside of Vehicle
a. Remove all clips and two driver side engine
guards from driver side wheel well.
b. Repeat above steps for passenger side.
c. Remove two bolts and brake line brackets
from driver and passenger side frame rails.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
d. Remove two bolts and parking brake cable
brackets from crossmember.
e. Remove two nuts and fuel line brackets from
driver side body.
f. Remove bolt and brake line bracket from driver
side frame.
14. Rear of Vehicle
a. Fuel Filler
1. Remove fuel filler cap.
2. Loosen two hose clamps and disconnect
vent hose connector.
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Use extreme caution when working near the fuel lines and the fuel tank. Clean up spilled fuel im- mediately. A spark could cause an explosion or fire resulting in serious personal injury and prop- erty damage.
WARNING!
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
3. Remove bolt and fuel filler from vehicle. 5. Remove six bolts from top side and four
bolts from bottom side of rear bumper.
b. Rear Bumper
1. Remove rear bumper wire harness from
driver and passenger frame.
15. Cab
a. Lift Cab
Install Kit
2, Remove two license plate lights from rear
bumper and remove trailer hitch harness.
3. Remove two license plate light sockets
from rear bumper and remove trailer electrical plug.
4. Remove plastic center section of rear
bumper.
1. Loosen, but DO NOT REMOVE cab
mounting bolts on driver side.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
NOTE
The number of cab mounting bolts may vary with the length of the cab.
2. Remove bolt, nut, and lower washer from
each cab mount on passenger side.
CAUTION
Continually check hoses, wires, lines, etc. to be sure that everything is flexing properly and not binding, or damage to the vehicle could result. Be especially careful of the a/c hoses at the fire wall, the belt pulley, and at the core support. Ensure brake lines stretch while lifting. Bending the lines to gain ample slack may be necessary. Be extremely careful not to kink the lines.
b. Cab passenger side
1. Remove captive washers from each
factory cab mount bolt. NOTE: The factory captive
washers will be used with kit bolts.
2. Position a hydraulic jack and a wood
block under passenger side of cab (under the body
seam). Slowly lift cab just enough to install a kit
block on top of factory upper bushing.
3. Install kit block (2” dia.) on upper
bushings on front core support cab mount.
4. Install kit blocks (3” dia.) on upper
bushings on each remaining cab mount.
5. Lower cab onto kit blocks.
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The kit blocks must be installed in addition to the factory upper and lower bushings. Installing the kit blocks without the factory upper and low- er bushings could result in damage to the vehi- cle and/or serious personal injury.
WARNING!
WARNING!
Use extreme caution when lifting body from frame. To prevent serious injury, ensure the lift- ing device is securely placed. Keep your hands out from between the body and frame.
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
6. Install factory front captive washer and a
kit bolt (M10 –1.25 x 190mm) on core support cab
mount. DO NOT TIGHTEN.
c. Cab driver side
1. Repeat previous steps on driver side of
cab.
7. Install factory mid captive washer and kit
bolt (M12 –1.75 x 180mm) on cab mount. DO NOT
TIGHTEN.
8. Install factory rear captive washer and kit
bolt (M12 –1.25 x 190mm) on cab mount. DO NOT
TIGHTEN.
2. Set cab-to-bed spacing according to
previous measurement.
3. Remove front core support cab mount kit
bolts (M10 –1.25 x 190mm) and apply a few drops
of kit Loctite® to threads. Install kit bolts , factory
captive washers, factory lower washers, and factory
nuts. Tighten kit bolts to 55 ft. lbs.
4. Remove mid cab mount kit bolts (M12 –
1.75 x 180mm) and apply a few drops of kit Loctite®
to threads. Install kit bolts, factory captive washers,
factory lower washers, and factory nuts. Tighten kit
bolts to 55 ft. lbs.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
5. Remove rear cab mount kit bolts (M12 –
1.25 x 190mm) and apply a few drops of kit Loctite®
to threads. Install kit bolts, factory captive washers,
factory lower washers, and factory nuts. Tighten kit
bolts to 55 ft. lbs.
16. Bed
a. Lift Bed
1. Loosen, but DO NOT REMOVE, bed
mounting bolts on driver side.
2. Remove bolt from each bed mount on
passenger side.
3. Bed passenger side
a. Remove captive washers from each
factory bed mount bolt.
NOTE
The factory captive washers will be used with kit bolts.
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NOTE
The number of bed mounting bolts may vary with the length of the bed.
Use extreme caution when lifting the bed from frame. To prevent serious injury, ensure the lift- ing device is securely placed. Keep your hands out from between the bed and frame.
WARNING!
To prevent damage to the vehicle while lifting the bed, continually check hoses, wires, brake lines, etc. to be sure that everything is flexing properly and not binding. Ensure clearance be- tween bed and cab is maintained.
CAUTION
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
b. Using hydraulic jack and a wood block,
slowly lift passenger side of bed a little more than 3”.
c. Install kit blocks (2” dia.) in frame
f. At rear mount, install kit bolt (M12 -1.25
x 160mm) and factory captive washer. DO NOT
TIGHTEN.
mounts.
bed.
g. Repeat previous steps on driver side of
h. Set bed-to-cab spacing according to
d. Lower bed onto kit blocks.
e. At front and mid bed mounts, install kit
bolts (M12 - 1.25 x 140mm) and factory captive
washers. DO NOT TIGHTEN.
previous measurement.
i. Remove each kit bolt, one at a time,
and apply a few drops of kit Loctite® to threads.
Install kit bolt with factory captive washer.
17. Rear of Vehicle
a. Rear Bumper
WARNING!
The following procedure is intended only to en- hance the appearance of the vehicle. The rear bumper will no longer be rated for towing of any kind. Towing with the rear bumper after it has been lifted can result in death, serious personal injury, or damage to the vehicle. Towing after the bumper has been lifted should be accom- plished using a rate Class III receiver type hitch.
NOTE
Rear bumper installation required kit# 5903.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
1. Mark and cut driver and passenger O.E
trailer hitch brackets along white lines as shown
below. NOTE: Be careful not to cut the welded nuts
on the factory brackets.
2. Apply a small amount of kit Loctite® onto
threads of two factory bolts and install kit bracket
(rear bumper, passenger). DO NOT TIGHTEN
3. Apply small amount of kit Loctite® onto
threads of two kit bolts and install kit bracket (lower
rear bumper, passenger) to passenger side bumper.
DO NOT TIGHTEN.
4. Apply small amount of kit Loctite® onto
threads of two factory bolts and install kit bracket
(bumper spacer) to center of bumper. DO NOT
TIGHTEN.
5. Repeat above steps for driver side.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
6. Mark and cut driver and passenger lower
mounts on bumper along white lines as shown
below. NOTE: Be careful not to cut the captive nuts
on the factory bumper.
7. Mark and cut driver and passenger
bottom side of bumper along white lines as shown
below.
8. Trim two plastic tabs on inside of bumper,
driver and passenger, by upper mounting holes as
shown below.
9. Install rear bumper using factory bolts for
lower driver and passenger mount.
10. Install rear bumper using kit bolts for
upper driver and passenger mount.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
11. Install rear bumper using kit bolts for
center mount.
12. Install license plate lights on rear
bumper.
13. Install rear bumper wiring harness on
frame, if possible.
14. Set bumper to previous bed-to-bumper
measurements.
15. TIGHTEN all rear bumper hardware.
B. Bumper cap 1. Once the rear bumper is installed locate bumper c ap and nut plate
Repeat for Driver side of vehicle. Make
Using the supplied 1/4-20 hardware align the bolts with the cover, bumper bracket and nut plate.
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
NOTE: Any and ALL bare metal parts from cutting or grinding should be coated with paint or anti rust/corrosion paint. 2. Cut fuel filler on cut lines. 3. Deburr edges of cut tubes.
b. Fuel filler
1. Mark fuel filler tubes with cut and
alignment lines.
2. Cut fuel filler on cut lines.
3. Deburr edges of cut tubes.
4. Install kit extension (1/4” x 6” hose)
between cut breather tube on fuel filler with two kit
clamps (#6 hose). DO NOT TIGHTEN
Use extreme caution when working near the fuel lines and the fuel tank. Clean up spilled fuel im- mediately. A spark could cause an explosion or fire resulting in serious personal injury and prop- erty damage.
WARNING!
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
5. Install kit extension (5/8” x 6” hose)
between cut vent tube on fuel filler with two kit
clamps (#10 hose). DO NOT TIGHTEN.
filler.
8. Install factory bolt onto frame and fuel
6. Install kit extension (1” x 6” hose)
between cut tube on fuel filler with two kit clamps
(#20 hose). DO NOT TIGHTEN.
7. Install fuel filler onto fuel tank with two
factory hose clamps and factory clip. DO NOT
TIGHTEN.
9. Adjust fuel filler and kit extension (hose)
to body.
10. TIGHTEN all hardware.
11. Install fuel filler cap.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
18. Underside of Vehicle
a. Parking brake cable
1. Install kit bracket (3” w/stud) to driver side
crossmember with factory bolt.
2, Install driver side parking brake cable to
kit bracket with kit nut (1/4” Nylock) and kit washer
(1/4” SAE).
3. Install kit bracket (3” w/stud) to
passenger side crossmember with factory bolt.
4, Install passenger side parking brake cable
to kit bracket with kit nut (1/4” Nylock) and kit
washer (1/4” SAE).
b. Fuel lines
1. Install kit bracket (2” stand off) to driver
stud with factory nut.
2. Install fuel line bracket to kit bracket (2”
stand off) with kit bolt (1/4” x 1”), two kit washers
(1/4” SAE), and kit nut (1/4” Nylock).
3. Install kit bracket (3” Z-shaped) to driver
side stud with factory nut.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
4. Install fuel line bracket to kit bracket (3” Z
-shaped) with kit bolt (1/4” x 1”), two kit washers
(1/4” SAE), and kit nut (1/4” Nylock).
c. Brake Lines
1. Carefully bend brake lines and install bolt
and brake line bracket to frame.
2. Install kit bracket (2” Z-shaped) and
factory bolt to driver side frame.
3. Install brake line bracket to kit bracket (2”
Z-shaped) with kit bolt (1/4” x 1”), two kit washers
(1/4” SAE), and kit nut (1/4” Nylock).
4. Repeat above steps for passenger side.
19. Inside of Vehicle
a. Extended cab models: Rear interior trim
panels.
2. Install drive rand passenger body mount
access plates and bolts.
3. Lay carpet down to cover driver and
passenger body mount access plates.
4. Install storage tray and pop-up clips to
vehicle.
5. Install jack into storage tray.
1. Install body mount access covers.
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b. Crew cab models: Rear interior trim panels.
1. Install body mount access covers.
2. Install passenger side rear panel onto cab
with pop-clips and bolt.
3. Install driver side rear panel onto cab with
pop-clips and three bolts.
c. Front interior trim panels
1. Install driver and passenger body mount
bolt access cover.
2. Lay carpet down to cover driver and
passenger body mount access covers.
3. Install driver and passenger kick panels.
4. Install dead pedal.
4. Return seatbacks to upright position and
install three headrests onto seatbacks.
plates.
5. Install driver and passenger door sill
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
d. Manual transmission
1. Remove plastic cap from end of shift
place.
5. Weld kit extension (manual shifter) in
lever.
2. Mark alignment and cut lines on shifter
lever below bend.
3. Cut shifter lever along marked cut line.
4. Position kit extension (manual shifter)
between two cut pieces of shifter lever. Ensure
alignment marks on each cut shifter lever piece are
aligned and rubber boot is on shift lever.
6. Grind off any excess welds.
7. Install plastic cap to end of shift lever.
8. Install shifter lever.
9. Install shift and center consoles.
20. Engine Compartment
a. Steering shaft.
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Welding should be performed by a certified welder.
WARNING!
Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
1. Replace factory steering coupler with kit
steering extension using a few drops of kit
Loctite® and kit bolts (3/8” x 1-1/4”).
2. Tighten bolts to 33 lb. –ft.
b. Radiator
1. Cut off tabs on upper radiator mounts.
2. Install four kit brackets (2” radiator) to
radiator mounts with four factory bolts. DO NOT
TIGHTEN.
3. Install radiator and four kit brackets to
core support with four kit washers (1/4” SAE and
four kit nuts (1/4” Nylock). DO NOT TIGHTEN.
4. Assemble kit plates (radiator block off)
with kit bolt (1/4” x 1”), two kit washers (1/4 SAE),
and kit nut (1/4” Nylock). DO NOT TIGHTEN.
5. Install kit plates (radiator block off) to
radiator with four factory pop-up clips.
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6. Install radiator cover to core support with
five factory pop-up clips.
7. Install radiator cover to kit plates (radiator
block off) with four kit clips (push) and four kit
washers (1/4” SAE).
8. Adjust radiator and ensure fan does not
contact fan shroud.
9. TIGHTEN all hardware.
c. Install wire harness and clips to alternator
bracket and driver side body bracket. Adjust clips if
necessary.
d. Install vent hoses to driver side body bracket
with kit tie (zip).
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e. Install driver and passenger brake line wire
harnesses to brackets with two kit ties (zip).
f. Install wire harness clip to firewall bracket.
g. Install heater hoses on clip and backside of
engine.
h. 6 cyl. Models: Power steering reservoir
1. Remove reservoir cap and drain contents
into drain pan.
2. Remove two clamps and power steering
lines from reservoir.
3. Mark power steering lines.
4. Cut power steering lines along cut marks.
5. Drain any remaining fluid from power
steering lines into drain pan.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
6. Install kit extension (7/16” OD x 5” L)
between cut power steering lines with two kit
clamps (#6 hose). DO NOT TIGHTEN.
7. Install kit extension (5/8” OD x 5” L)
between cut power steering lines with two kit
clamps (#10 hose). DO NOT TIGHTEN.
8. Install power steering reservoir, lines,
clamps, and three bolts onto vehicle.
9. Adjust hoses and tighten all hardware.
i. 4 cyl. Models: Power steering requires no
modification.
j. 6 cyl. Models: AC line
1. Install rubber isolator to body.
2. Install AC line and clamp onto rubber
isolator with nut.
k. 4 cyl. Models: AC line
1. Install kit bracket (3” Z-shaped) to
passenger side AZ line bracket with bolt.
2. Install AC line to bottom of kit bracket (3”
Z-shaped) with kit bolt (1/4” x 1”), two kit washers
(1/4” SAE), and kit nut (1/4” Nylock).
3. Install kit bracket (3” w/stud) to rubber
isolator and passenger side AC line bracket with nut.
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Tactical # 4004101 Toyota Tacoma Toll Free # 800.595.7659
4. Install AC line to kit bracket (3” w/stud)
with kit washer (1/4” SAE), and kit nut (1/4”
Nylock).
l. 6 cyl. Models: Install airbox cover to engine
with two clips. Tighten clamp.
m. 4 cyl. Models: Install air hose to engine with
two clips. Tighten clamps.
21. Front of Vehicle
a. Automatic transmission cooler: (if equipped)
NOTE
Parts to perform the automatic transmission modification are included in Kit# 5903. The auto- matic transmission cooler is a factory option with the tow package.
1. Cut short trans cooler line as shown.
2. Insert kit extension (tube 7/16”) into cur
transmission cooler line with two kit clamps (#6
hose). TIGHTEN two kit clamps (#6 hose).
3. Install two kit extension (sleeve), two kit
bolts (8mm x 50mm), two kit washers (8mm flat),
and automatic transmission cooler lines to lower
core support.
4. Install automatic transmission cooler onto
core support with four bolts.
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b. Power steering cooler relocation
1. Install 2” kit bracket (w/stud) to move
cooler toward radiator, passenger side.
2. Install 2” kit bracket (w/stud) to move
power steering cooler lines toward rear of vehicle,
passenger side.
3. Install 2” kit bracket (w/stud) to move
cooler toward radiator, driver side.
c. Front Bumper
1. Apply a small a mount of kit Loctite® to
six factory studs and install kit brackets (front
bumper) to frame with six factory nuts.
2. Apply a small a mount of kit Loctite® to
six kit bolts (3/8” x 1”) and install front bumper to kit
brackets (front bumper) with twelve kit washers
(3/8” USS) and six kit nuts (3/8” Nylock).
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3. Install front bumper cover to vehicle with
six factory screws.
4. Install two pop-up clips to fender wells.
5. Install five pop-up clips to front bumper.
6. Install two pop-up clips, two bolts, and grill
to core support.
7. Install wiring harnesses to fog lights, if
equipped.
8. Adjust bumper and tighten all hardware.
22. Leveling Kit Installation
a. Ensure
the upper a-arm and spindle (10mm and 12mm
bolts). NOTE: If your vehicle is equipped with the X-
REAS hydraulic shocks system, DO NOT open or
disconnect any of the shocks hydraulic lines ot it’s
system during this install.
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c. Disconnect the sway bar on both sides at the
spindle (17mm bolt).
d. Remove the upper strut nuts (14mm), you will
need to reuse them later.
e. Remove upper ball joint nut (19mm) and
separate the ball joint from the spindle by hitting the
side of the spindle. DO NOT use a ball joint
separator tool, it can damage the ball joint boot.
f. Remove the lower strut bolt and nut (19mm).
g. Remove the strut from the vehicle.
h. Install the stud extenders and spacer on the
top of the strut plate.
i. Reinstall the strut to the vehicle and tighten the
upper strut nuts. You will have to push up on the
upper a-arm to get the strut back in.
k. Reinstall the suspension working in reverse
order.
IMPORTANT NOTE: The advertised amount of lift that
this kit provides and the thickness of the spacers supplied
will not be the same! For example, a 2-1/2” lift may only
have 1-1/2” thick spacers. The reason for the difference
between the spacer thickness and the amount of lift has
to do with suspension geometry. There is a ratio
involved, and it is this ratio that determines the thickness
of the spacers. Rest assured, installing the spacer
supplied will result in the proper amount of lift out at the
wheel.
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After Completing Installation 23. Inside Cab
a. Install airbag fuse and fuse block cover.
24. Engine Compartment
a. Connect both battery cables. Connect
positive cable first, then negative cable.
25. Miscellaneous
a. Apply kit label (warning) to dashboard in plain
sight of all vehicle occupants.
b. Check all fasteners to ensure they are tight.
c. Ensure all wires, hoses, cables, etc., are
properly connected and there is ample slack.
d. Fill and check power steering reservoir with
fresh power steering fluid. Start engine and turn
wheel several times in either direction. Shut off
engine and recheck power steering reservoir. Add
fluid, if necessary.
25. Dynamic Vehicle Check
a. Check steering in both directions to ensure
that there is no bind. Check operation of clutch,
brake system, and parking brake. Check operation
of transmission and transfer case. Ensure there is
full engagement in all gears and 4WD ranges. Check
battery connections and electrical component
operations. Test-drive vehicle.
NOTE
DayStar recommends that you have your wheel alignment checked.
CAUTION
DayStar does not recommend any particular wheel and tire combinations for use with its body lifts and cannot assume responsibility for the customer’s choice of wheels and tires. Refer to your owner's manual for recommended tire sizes and warnings related to the use of oversized tires. Larger wheel and tire combinations in- crease stress and wear on steering and suspen- sion components, which leads to increased maintenance and higher risk for component fail- ure. Larger wheel and tire combinations also al- ter speedometer calibration, braking effective- ness, center of gravity, and handling characteris- tics. Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle.
3 1
Retorque all fasteners after 500 miles and after off road use. All body lift components should be visually inspected and fasteners retorqued dur- ing routine vehicle servicing.
WARNING!