Step 1: Prepare mounting brackets. Remove mounting brackets from all 6 (six)
lights. Set aside switches
and wiring packet for later use. Use
a pair of pliers and bend the rear tabs of the brackets up like
the following picture.
Stick the double-sided foam mounting pads to the bottom of the mounting
Step 2: Prepare lights. Cut the bullet style connector
from the end of each ground (black) wire. Strip ¼" of
insulation from each black wire, and install a ¼" ring terminal on
Note: If you are going to install the
Angle Bar reversed to carry a Hi-Lift ® style jack or other
heavy item, skip to next Step 3-Alternate.
Step 3: Install
light brackets and ground wires. Lay the long Angle Bar from the Hood Rack
on a flat surface as illustrated below. Note that in this position the Light Bar is upside down (i.e. the
silver Tough Stuff emblem will be on the TOP when installed). Peel the release paper from the foam mounting
pads and align them as desired, if you want them all straight
ahead, align the brackets to sit 1/8" back from the front edge
of the Angle Bracket like the following photograph. Use the 1/4" Diameter
X 5/8" long allen head bolts and ¼" nyloc nuts (as illustrated)
to secure the brackets in place. Place a toothed lock washer under the head
of each of these bolts (i.e. on TOP of the Light Bar). This toothed washer assures an electrical
ground connection through the powder coated finish.
Note the position of the ground wire
underneath the nut
You can also angle the brackets to illuminate the sides of the trail like
Step 4: Install the lights. Each
light mounts to the brackets using two 10 mm head size bolts; one
on each end. New Stainless
Steel bolts are provided to replace the bolts supplied with the
lights, which tend to rust easily. The
bolt will slide in the groove in the bracket, which allows you
to set the lights height and angle of direction. Note that there is a small vent on the bottom
(top as you are installing) of the light for a condensation drain. You may find it easier to use a spacer between
the light and Angle Bar or a long traightedge to set all the lights
to the same height.
This picture is of the
bottom as you see it while installing the lights. Skip to Step 5.
Step 3-Alternate: Mounting light brackets for use while Angle
Bar is reversed for heavy items. Lay
Angle Bar on a flat surface with the longer leg down as illustrated
below. Peel the release
paper from the foam mounting pads. Install
4 (four) brackets only, in the center 4 holes as illustrated. Note where the allen head of the bolt is located. Place a toothed lock washer under the Nyloc
nut (NOT the allen head) on each of these bolts. This toothed washer assures an electrical ground connection through
the powder coated finish. The
last 2 brackets will be installed later when you mount the Angle
Bar on the Jeep®.
Step 4-Alternate: Install the lights. Each light mounts to the brackets using two
10 mm bolts; one on each end. New
Stainless Steel bolts are provided to replace the bolts supplied with
the lights, which tend to rust easily. The
bolt will slide in the groove in the bracket, which allows you to set
the lights height and angle of direction. Note
that there is a small vent on the bottom (top as you are installing)
of the light for a condensation drain. You
may find it easier to use a spacer between the light and Angle Bar
or a long straightedge to set all the lights to the same height.
This picture is of the bottom as you see it while installing the lights
for Alternate Angle Bar mounting.
Step 5: Wiring the
the following white wires with double female ends from the hardware
kit that comes with the lights and cut them to the specified
length. Strip the insulation about ½" from the ends
of the wire.
Twist the 3 wires together and install
the yellow butt connector with a crimping tool, then attach the
long, black 14 gauge wire to the other side of the yellow butt
connector as pictured. Pull
on each of the wires to check the connection tightness.
Step 6: Attach wiring harness to lights. Place the long 14 gauge black wire
on the left side of the Angle Bar (driver's side). Plug 2 lights into each connector. If using the alternate method above, only plug one light into the
shortest and longest wire, the mid-length wire will plug into the
2 center lights. Route
the wires around and behind the brackets so they will not be visible,
use the supplied nylon ties to secure the wires.
Step 7: Install Angle Bar as directed in the Hood Rack instructions, with
two differences. Place 2 each 5/16" toothed lock washers
under both the allen head and the Nyloc nut on one of the 5/16" mounting
bolts. Also place one
under the head of one of the 3 mounting bolts on the Hinge Bracket
that goes into the hood. These
toothed washers assure an electrical ground connection through
the powder coated finish.
If using Alternate method: Use
the 2 innermost 5/16" allen head mounting bolts to mount
the 2 light brackets. Tighten
the bolts fully and then slightly bend the bracket around the other
bolt head. See the following photograph. The slotted holes will allow adjustment to
compensate for the bend. Install
the last 2 lights and hook up wiring as explained above. Install toothed lock washers as explained in step 7.
ground wire is not shown for clarity.
Step 8: Route 14 gauge black wire into engine compartment. Look for the easiest route to
run the wire down beside the driver's side Hood Bracket and into
the engine compartment without pinching the wire. A
rubber grommet is supplied that may be placed in the rear angle
of the hood and the wire routed through it. Drill
a ¼" hole to install the grommet. Paint
the edges of the hole for rust prevention. See the following photograph.
Step 9: Secure wire to Hood Hinge Bracket. Route wire as shown below and
secure with black nylon ties. You
may need to remove the Hood Bracket and trim a little of the gasket
to install the nylon tie in the oval hole. You
may need to hold the rubber grommet in with a small adjustable
wrench while pushing the wire through.
Step 10: Finish wiring. Locate
a place to mount the relay and switch/switches, and finish the
wiring for your specific vehicle per the following diagram.
Some states require an under hood "lockout" switch
for auxiliary lights. Two switches are shown in this diagram to
assure compliance with local laws.
The switches contain a built-in pilot
light that will illuminate when the switch is in the "ON" position. To disable the pilot light simply do not connect
the Ground wire to the switch.
NOTE: If your lights do
not work after installation, check the location of all toothed
washers, they must be in the locations specified. Then
re-tighten all bolts with toothed lock washers. The grounding circuit must be completed through these washers. They
MUST bite through the powder coated finish and make contact with
bare metal in every location specified. Also
check the factory grounding strap to your hood for continuity.