Daystar KJ60016 - Manual

Shackle Installation Instructions
CAUTION: BEFORE BEGINNING INSTALLATION, READ
ALL INSTRUCTIONS CAREFULLY AND COMPLETELY.
1. Park vehicle on level work area and set emergency brake. Block tires opposite of the
ones being lifted. Lift one end of the vehicle using the floor jack until the wheels clear
the ground about 3”. Place jack stands under frame rail behind inner spring perch.
Lower vehicle onto jack stands with axle supported by floor jack.
2. Carefully remove upper and lower spring shackle mounting hardware, left, and right
shackle plates. Lower axle carefully until the wheels touch the ground. Make sure that
the brake line and the vent line is not over stretched.
3. If installing a Greaseable Super Shackle, remove the spring eye bushing/steel sleeve
assembly from the spring eyes. Clean with a wire brush or sandpaper.
4. Install the corresponding bushings into the spring eye and into the frame and lubricate
with silicon or Teflon lubricant. Daystar Lubrethane Poly Lube is recommended. Install
the steel sleeves if provided.
5. Install the shackles onto the frame. Shackles with the off-center support, install the long
end up towards the frame and the short end down goes towards the spring. See figure
1. Shackles with the off-set center support need to be inboard. See figure 2 and 3. The
center support is designed to eliminate shackle flex. (When going to longer shackles,
you are raising the center of gravity, which tends to make the vehicle over-steer. By
welding a center support in the shackle, it eliminates the sway and spring roll improving
the handling characteristics and side flex for off road purposes.)
6. Install the upper bolts. Tighten the nuts so the shackles swing freely. Do not over-
tighten the nuts or the shacke will bind causing a stiff ride and limiting suspension
travel.
7. Using the floor jack raise the rear axle until the spring eye aligns with the shackle.
Insert the bolt. Tighten the nut to manufactures specifications. DO NOT OVER-
TIGHTEN BOLTS AND NUTS! Damage to shackle could result!
8. You will not need to worry about driveline vibration due to changing pinion (driveline)
angle. You are working on a fulcrum so as you lift, you pivot the pumpkin-differential
and pinion (driveline) at the same time. If you have a drive-shaft vibration first check the
universal joints for wear. If the universal joints are good, on taller lifts you might need to
install degree shims between the axle housing and the spring to change your pinion
(driveline) angle. On many vehicles you can drop the transfer case down from the
frame which will also change the pinion (driveline) angle.
9. On greaseable shackles, grease the shackle bolts with silicon or Teflon lubricant.
Daystar Lubrethane Poly Lube is recommended after installation.
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
Instruction Sheet P10519-00
 2000 Daystar Products International Inc.
Typical Bill Of Material
Greaseable Shackles Non Greaseable Shackles
Description Qty. Description Qty.
Shackles 2 Shackles 2
Bolts 4 Bolts 4
Nuts 4 Nuts 4
Bushings 8
Steel Sleeves 4
NOTE: Not all greaseable kits
come with steel sleeves
Fig. 2
Fig. 3
Fig. 1
WARNING
This vehicle has been modified to enhance its
performance. The steering, braking and handling of this
vehicle will differ from standard passenger cars and
trucks, This vehicle handles differently from an ordinary
vehicle in driving conditions which may occur on streets,
highways and off road.
Avoid unnecessary abrupt maneuvers, sudden stops,
sharp turns and other driving conditions that could cause
loss of control, possibly leading to a roll over or other
accident that could result in serious injury or death to
driver and passengers.
If larger tires are installed the speedometer will read
lower than the vehicles actual speed.
DRIVE WITH CARE, REDUCE SPEED
AND WEAR SEAT BELTS AT ALL TIMES.
This kit should be installed by a professional mechanic