UPTOP PN 4090 Universal Light Bar Brackets Instruction Manual
- June 10, 2024
- upTOP
Table of Contents
UPTOP PN 4090 Universal Light Bar Brackets
Thank you for selecting upTOP™ as the choice for your vehicle. The product included in this kit is designed to facilitate the secure mounting of most light bars up to 40” (101cm) into your roof rack. This product is compatible with extrusions with a face surface of 2.00” (50mm) equipped with two (2) slide tracks for hardware accepting M6 or 1/4-20 sized hardware.
Product Information
Universal Light Bar Brackets PN 4090
The Universal Light Bar Brackets PN 4090 are designed to facilitate the
secure mounting of most light bars up to 40 inches (101cm) onto your roof
rack. These brackets are compatible with extrusions that have a face surface
of 2.00 inches (50mm) and are equipped with two slide tracks for hardware
accepting M6 or 1/4-20 sized hardware. Your kit includes two identical
brackets, which are not indexed as driver/passenger side, and an Allen wrench.
Compatibility
Although these brackets are intended for use with most light bars, there might be compatibility issues during installation. However, these brackets have been tested on all major brands with great success. If you need assistance during installation, feel free to contact us Monday-Friday from 8am to 4pm Mountain time at 720.730.6381 or email support@uptopoverland.com.
Product Usage Instructions
- Ensure that the extrusions on your roof rack have a face surface of 2.00 inches (50mm) and are equipped with two slide tracks for hardware accepting M6 or 1/4-20 sized hardware.
- Choose the slot on the slide tracks of the extrusions that is compatible with your light bar through trial and error.
- Insert the included Allen wrench into the bracket’s hole on the slide track.
- Use a 7/16 wrench or socket to tighten the bracket onto the extrusion.
- Repeat steps 3 and 4 for the other bracket.
- Slide the front load bar of your light bar onto the brackets and nest it close to your front windscreen.
- Leave a gap of around .250 inches (6mm) between the light bar and the load bar.
- Adjust the position of the light bar by sliding the front load bar backwards or forwards until you find the perfect mounting location.
- Ensure a tight fit to minimize wind noise.
TOOLS REQUIRED
- 5/32 Allen wrench
- 7/16” wrench (Alpha only)
- 5mm Allen wrench (Alpha only)
PARTS INCLUDED
- 4090 Light bar bracket (Qty 2)
- Threaded track inserts (Qty 4)
- 4090 anchor bolts (Qty 4)
- Flat Washers (Qty 4)
NOTICE
This mounting kit DOES NOT include hardware for attaching your light bar to
the brackets. Each light bar has unique thread pitch and accepted hardware
depth and there are too many variants on the market to include hardware for
each model. It is critical that you use the hardware provided with your light
bar to attach the light bar to the 4090 brackets. If your light bar did not
arrive with mounting hardware or you need alternate hardware it is the
responsibility of the end user of this product to source and verify proper
thread requirements have been met prior to completing installation. Failure to
use the proper hardware for your lighter can result in damage to the threads
of the light bar housing that may be irreparable and void your light bar
warranty. By using this product you release upTOP from liability claims of
damage to your light bar(s).
Although intended for use with most light bars you might face compatibility
issues during installation. We have tested these brackets on all major brands
with great success. Should you need assistance during installation feel free
to contact us Monday-Friday from 8am to 4pm Mountain time at 720.730.6381 or
email support@uptopoverland.com.
INSTALLATION
Your kit includes two (2) of the 4090 light bar brackets pictured to the left. The brackets are identical and are not indexed as driver/passenger side. ****
First you will need to remove one (1) side hardware set of the front load bar of your roof rack.
- For Bravo and Zulu roof racks you will use a 5/32” Allen wrench.
- For Alpha roof racks you will need to remove the armor first so you will need a 5mm Allen wrench and a 7/16” wrench or socket. An 11mm wrench or socket will also work.
- Gain access to the end of the front load bar and insert two (2) of the threaded inserts into each channel as shown to the right.
- Re-install the front load bar (and armor if equipped).
Next you will install both of the brackets. As mentioned above they are the same part so it doesn’t matter which side you put them on.
- Align the threaded inserts to the holes in the bracket as indicated to the left. Each hole will receive:
- Hex Bolt
- Flat Washer
- Snug the fasteners in place but do not fully tighten. You will need to adjust them into position to align to your light bar.
- Install the second bracket with the remaining hardware using the other two threaded inserts in your load bar.
NOTICE
Use only hardware supplied with your light bar for this step. See front page
of this document for clarification.
- Align your hardware to the slot(s) in the 4090 bracket that are compatible with your light bar. Trial and error will determine which slot works best for your light bar.
- Snug your hardware into place but do not fully tighten to aide in alignment of the light bar later.
- Align and mate the other end of the light bar.
Now you are ready to align your light bar into your roof rack.
- All upTOP roof racks load bars feature depth adjustment in the front location to help zero in the perfect mounting location for your light bar. Simply slide the front load bar backwards or forwards to nest close to your front wind screen. Leave a gap of around .250” (6mm) and remember, the tighter the fit the less wind noise you have to deal with. Some light bars are inherently noisy.
- Slide the light bar brackets side to side to center the light bar in the windscreen. Depending on the light bar you are using you might have collision with the light bar brackets protruding through the angled tabs of your windscreen. You may be required to slide the load bar back further than anticipated to gain required clearance.
- Once your light bar is aligned to your liking tighten all of the hardware with the required tools. For upTOP supplied hardware the torque specifications require 3.5 Ft. Lb.
- Refer to your light bar manufacturer for appropriate torque for light bar related hardware.
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