9. Using extreme caution, tighten the puller tool enough to
take the load off the adjuster bolt. Remove the adjuster
bolt and nut block, then unload the puller tool.
10. Note the orientation of the torsion bar key in relation to
the end of the torsion bar. Slide the torsion bar forward,
out of the torsion bar crossmember, and set the factory
torsion bar key aside. It is not necessary to remove the
torsion bars from the vehicle. NOTE: the torsion key
should slide easily off the end of the torsion bar. How-
ever, depending on the age and use of the vehicle, rust
and road debris may prevent easy removal. The installer
can use a variety of methods to separate the torsion key if
it is “stuck”, but using heat is not recommended.
11. Place the Daystar torsion key in the torsion bar cross-
member, matching the same orientation as the original
key. Slide the torsion bar back through the crossmember
and into the torsion key. See Figure 2.
NOTE: Various types of puller tools are available, however, due to the
extreme loads present in four-wheel drive suspension systems, we have
found the two-jaw style tool that clamps to the crossmember tends to slip
and damage the crossmember. A C-clamp style puller tool is preferred
and available through tool companies such as OTC and Kent Moore.
Notice to Dealer and Vehicle Owner
Any vehicle equipped with any Daystar Product must have the
“Warning to driver” decal installed on the sun visor or dash. The
decal is to act a constant reminder for whoever is operating the ve-
hicle of its unique handling characteristics. INSTALLING
DEALER— Its is your responsibility to install the warning decal
and forward these instructions on to the vehicle owner for review
and to be kept in the vehicle for service life.
After installation occurs, a qualified alignment facility is required to
align the vehicle to factory specs.
NOTES:
• Installation requires a professional Mechanic.
• Have a factory service manual on hand for reference and for
appropriate torque specifications.
• WARNING: Torsion bars have a tremendous amount of energy
stored in them, even with the suspension at full extension travel.
Safely loading / unloading the torsion bars requires a special
tool. Refer to the factory service manual. Use extreme caution
when working with torsion bars and wear all appropriate safety
equipment.
• Read through all installation steps before proceeding. If you
have questions, contact Daystar before beginning the installation.
(2 pages)
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