Daystar KJ60013 User Manual

Shackle installation instructions

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This manual is related to the following products:

KJ60011 KJ60010 KJ60004 KJ60012 KJ60006 KJ60008 KJ60001 KJ60009 KJ60002 KJ60007 KJ05006BK KJ60003

Table of contents

Document Outline

DO NOT COMBINE WITH ANY OTHER SUSPENSION KIT
CAUTION: BEFORE BEGINNING INSTALLATION, READ ALL INSTRUCTIONS CAREFULLY AND COMPLETELY.
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. See figure 1. Some of the frame shackle bushings need to be burnt out leaving the steel outer shell in the frame. Do not damage the outer shell. Clean with a wire brush or sandpaper.
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. See figure 2 and 3. Install the steel sleeves if provided.
Install the shackles onto the frame. Shackles with the off-center tube, install the long end up towards the frame and the short end down goes towards the spring. 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 tube 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. DO NOT OVER-TIGHTEN BOLTS AND NUTS! Damage to shackle could result!
9. On greaseable shackles, grease the shackle bolts with silicon or Teflon lubricant. Daystar Lubrethane Poly Lube is recommended after installation.