baja designs 21+ Ford Bronco Roof Lighting kit Instructions

baja designs 21+ Ford Bronco Roof Lighting kit

Product Information

The Ford Bronco (21+) Roof Lighting Kit is designed to enhance visibility and provide additional lighting options for your vehicle. This kit comes with a limited lifetime warranty, ensuring its durability and performance.

Tools Required

• Screwdriver – T30 Torx bit
• Trim tool
• 10mm socket
• 7/16 wrench and socket

Product Usage Instructions

1. Ensure the vehicle is in park, turned off, and disconnect the negative battery terminal using a 1/2 wrench.
2. Using a trim tool, press in the tab on the accessory ready mount cover on one side of the upper windshield frame and remove. Repeat for the other side. (Refer to page 277 of the Bronco Owner’s Manual for more details)
3. Using a 10mm socket, remove the two nuts and plastic cover mounts on each side.
4. Locate the roof mounting brackets and the rubber bump hardware.
5. Using a 7/16 wrench and socket, thread one bolt through a large washer, the recess side of the rubber bumper, up the long slot in the mounting bracket, through another washer, and tighten into the nut. Leave the hardware loose enough to adjust along the slot. Repeat for the other side.
6. Using nuts, mount the driver side bracket and tighten slightly. Adjust the rubber bump along the slot to the front of the vehicle. This will allow the locking nuts to capture the maximum thread engagement on the windshield studs. These nuts will be tightened later after adjusting the width of the brackets.
7. For OnX6+ and S8 kits only: Locate the OnX6+/S8 parts bag and remove the 7/16 hex head hardware. The longer bolts will be used in the rear mounting holes on the arced slot of the bracket (OnX6+ only). The shorter bolts are for the front mounts.
8. An assistant will be needed for this step. Hold the lightbar up to the roof mounts and adjust the width of the brackets as necessary. Hand thread in the light endcap hardware using the provided washers from the parts bag. Adjust the front face of the light vertical for now and tighten with the 7/16 socket. Once the harness is operational, you will adjust these bolts to aim the light.
9. Tighten the nuts from step 6 to 7.7 lb.ft (10.5 Nm). With a minimal amount of force, lift on the roof bracket and slide the rubber bump as far back as it will go. This will help absorb shock and vibration. Repeat for the other side.
10. For Linkable kits only: Place the 8 XL Linkable onto a soft work surface. With the provided 10 Allen wrench in the XL Linkable parts bag, remove the top and bottom bolts of the center pair of links. On one of the two center lights, left or right, remove the housing bolts with the provided Allen wrench.
11. Locate the preload extension brackets with hardware. With the 7/16 wrench and socket, attach the rubber bump as shown to the base support bracket. With the longer bolts in the support bracket parts bag, reattach the link to the light with the extension bracket in between the link and the light housing. Leave the bolts loose enough for adjustment.

Note: Refer to the specific instructions for OnX6+ and S8 kits or Linkable kits for further details on mounting and usage.

LIMITED LIFETIME WARRANTY

Baja Designs proudly offers a LIFETIME WARRANTY against manufacturer’s defect on all the products that we manufacture. These are comprehensive warranties; other than the exclusions below – you’re covered. If your LED or HID bulb burns out, you’re covered. Additionally, cutting off our connector or changing your lenses does not automatically void your warranty.

Exclusions

Installation errors, abuse, misuse or crash damage. You must be the original owner of the product and can supply proof of purchase. Baja Designs manufactures its own products as well as resells products manufactured by others. Baja Designs makes no express or implied warranties on products not manufactured by Baja Designs including without limitation any warranties or merchantability and fitness for a purpose. We will, however, pass on all warranties made by the manufacturer, who has sole responsibility for performing such warranties.

Baja Designs will pay the freight if your product is less than 90 days old, otherwise defective products must be returned to Baja Designs, Inc., freight prepaid. At our option, we will repair or replace items in question and return them at no charge. If the identical product is no longer available, we will replace with a similar product of equal value. Baja Designs Inc. will not be responsible for any indirect or consequential damages in connection with defective merchandise.
Items purchased through a Baja Designs authorized dealer must be returned through the dealer. Only available on LED auxiliary lights and product must be in sellable condition at MSRP. Product that has been damaged in any way after the original purchase date will be excluded from this guarantee.

Indemnification

Buyer hereby acknowledges off-roading, racing and driving at night are dangerous activities and that the products and/or supplies purchased from Baja Designs are used in an inherently dangerous activity that may endanger life and limb; and in no event shall the seller, or seller’s heirs and assigns, be held liable for consequential damages, nor shall seller’s liability on any claim for damages arising out of or connected with the sale, delivery, or use of purchased products and/or supplies exceed the purchase price of the products and/or supplies. Buyer is responsible for ensuring that it uses the products (and its vehicle) in accordance with all applicable laws, regulations, guidelines, and standards of care. Buyer acknowledges that some products may only be used when off-roading, and Buyer will comply with all vehicle and road safety guidelines. Buyer is solely responsible for (and will indemnify and hold Bestop harmless for) any claims, losses, damages, fines, fees, costs, or other amounts arising out of Buyer’s non-compliance with these provisions.

Tools Required

• 10mm and ½” Wrench (battery tools)
• Pliers
• Trim tool (preferred), or flathead screwdriver
• T30 Torx bit
• ¾ Drill (non-upfitter models)
• 7/16”, and 10mm Sockets
• 7/16” wrench
• Electrical tape

Installation Instructions

1. To begin, place the vehicle in park, turn off and disconnect the negative battery terminal (1/2” wrench).
2. With the trim tool, press in the tab on the accessory ready mount cover on one side of the upper windshield frame and remove. Repeat for the other side. (Page 277, Bronco Owner’s Manual)
3. With the 10mm socket, remove the two nuts and plastic cover mounts on each side.
4. Locate the roof mounting brackets and the rubber bump hardware (two 1/4”-20 x 1” long hex head bolts, two ¼” nyloc nuts, and four large ¼” washers).
5. This step will use the 7/16” wrench and socket. Thread one bolt through a large washer, the recess side of the rubber bumper, up the long slot in the mounting bracket, through another washer, and tighten into the nut. Leave the hardware loose enough to adjust along the slot. It will not need to be tightened later. (Driver side bracket shown) Repeat for the other side.
6. With the 10mm socket, the large ¼” washers, and M6 nylon lock nuts, mount the driver side bracket as shown and tighten slightly. Adjust the rubber bump along the slot to the front of the vehicle. This will allow the locking nuts to capture the maximum thread engagement on the windshield studs. These nuts will be tightened later after adjusting the width of the brackets.
   • Steps 7 through 9 are for OnX6+ and S8 kits only: **S8 only uses front mounting hardware.
7. Locate the OnX6+/S8 parts bag and remove the 7/16” hex head hardware. The longer bolts will be used in the rear mounting holes on the arced slot of the bracket (OnX6+ only). The shorter bolts are for the front mounts.
8. An assistant will be needed for this step. Hold the lightbar up to the roof mounts and adjust the width of the brackets as necessary. Hand thread in the light endcap hardware using the provided washers from the parts bag. Adjust the front face of the light vertical for now and tighten with the 7/16” socket. Once harness is operational, you will adjust these bolts to aim the light.
9. Tighten the nuts from step 6 to 7.7 lb.ft (10.5 Nm). With a minimal amount of force, lift on the roof bracket and slide the rubber bump as far back as it will go. This will help absorb shock and vibration. Repeat for the other side.
   • Steps 10 through 16 are for Linkable kits only:
10. Place the 8 XL Linkable onto a soft work surface. With the provided Allen wrench in the XL Linkable parts bag, remove the top and bottom bolts of the center pair of links. On one of the two center lights, left or right, remove the housing bolts with the provided Allen wrench.
11. Locate the preload extension brackets with hardware. With the 7/16” wrench and socket, attach the rubber bump as shown to the base support bracket (#8 in Figure 3,XL Linkable Instructions). With the longer bolts in the support bracket parts bag, reattach the link to the light with the extension bracket (#14 in Figure 3, XL Linkable Instructions) in between the link and the light housing. Leave the bolts slightly loose for now.
12. With the provided Allen wrench, replace the bolts from step 10 and reassemble the Linkable light bar. To arc the light bar: One at a time, loosen each pair of links and adjust so the edges are parallel as shown. Tighten. The outer two pairs of links can remain loose momentarily.
13. With the provided Linkable mounting hardware, Allen wrench and 7/16” socket, mount the lightbar onto the roof brackets. Tighten. After light is operational, adjust this hardware to aim.
14. Tighten the nuts from step 6 to 7.7 lb.ft (10.5 Nm). With a minimal amount of force, lift on the roof bracket and slide the rubber bump as far back as it will go. This will help absorb shock and vibration. Repeat for the other side.
15. Tighten the top and bottom bolts on the end links. Tighten the preload extension bracket bolts from end of step 11.
16. Remove the hard or soft top above the front seats. Have an assistant pull up on the light bar center, while pushing down on the preload support base bracket, and tighten the hardware with the 7/16” wrench and socket.
    • All kits:
17. The main harness (upfitter or toggle switch) will need to be unraveled. Route the light lead of the harness along the top of the firewall away from any hot, sharp, and/or rotating components. Continue routing the harness over the hood hinge. (OnX6 Dual Control Only: repeat for second harness to the driver side).
18. With the T30 Torx bit, remove the two circled Accessory Ready bolts on the passenger side shown. Remove the antenna. With the trim tool, pry up on the windshield wiper cowling plastic until there is a large enough gap to route the wiring harness behind (Second image). The harness will leave the wiper cowling in the very bottom corner arrowed in the first image. Pull enough slack in the harness to reach the light power cord. Connect the harness to the light. (OnX6 Dual Control Only: repeat for second harness to the driver side).
    • OnX6+/S8 Only: the light power cord can be tied back to itself with an included zip tie to keep the connector behind the bracket when viewed from the passenger side. Pull the wiring harness tight against the windshield on the passenger side.
19. Use provided zip ties and anchors to adhere the harness to the windshield (Image on next page). Remove the slack from inside the wiper cowling plastic and tie the harness as needed across the firewall. Replace the antenna and Accessory Ready bolts with the T30 Torx bit.
20. S8 Backlight wiring: us the provided fuse tap kit to tap into the fuse panel behind the headlight controls panel to tap off the 5A fuse in the #35 location. (See fuse tap kit instructions)
21. If you purchased the Upfitter switch version:
    • Locate the bundle of upfitter wires in the back driver side corner taped to the large wiring harness. Pull the tape off to access the wires.
    • The Upfitter wire ratings are shown in the table. AUX1 should be used for all kits.
    • (OnX6 Dual Control Only: use AUX1 for non-relay harness and any other switch for the additional relay harness. Relay harness will need to be attached to battery).
    • Using the pliers, clasp the splice connector of the upfitter splice harness over the desired wire/circuit. Repeat for second harness. Wrap the tape back over the remaining wires. Make sure all wires are isolated and add electrical tape as needed.
    • Mount the black ring terminal of the splice harnesses to the common ground on the driver side firewall using a 10mm socket wrench.
    • Reattach battery ground (-).
22. If you purchased the stand-alone toggle switch version:
    • Locate the firewall passthrough grommet on the right side of the brake booster. In the cab, this will be located next to the footrest. Push grommet into engine compartment from the cab.
    • There are two easy options for switch locations on the dash in the locations arrowed under the headlight controls.
    • Gently pull dash panel away until unclipped. Locate the two circled indentations on the back of the dash below the headlight controls. These are the two suggested switch mounting locations.
    • Snap a photo of the switch wiring for reference later. Remove the switch terminals from the switches. Remove the tape around the wires on either side of the passthrough grommet.
    • Choose the desired dash locations for the switches. Drill ¾” hole.
    • Thread the wires through the hole in the passthrough grommet, reattach switch terminals, and mount switch. Tape around the wires of the grommet. Install dash panel.
    • Mount the (+) and (-) ring terminals of the harness to the corresponding battery terminals starting with the (+) red lead.
    • (OnX6 Dual Control Only: repeat for second harness).
    • Reattach battery ground (-)

Tie all wires away from sharp, hot, and/or rotating components.
Re-torque all the fasteners after 100 miles.
Your install is now complete! Thank you for choosing Baja Designs.

Contact

• 2950 Norman Strasse Rd San Marcos CA • 92069
• Phone: 760-560-2252 X3
• Fax: 760-560-0383
• [email protected]
• www.bajadesigns.com

References

• The Scientists of Lighting | Home - Baja Designs - Off-Road LED & Laser Lights | Automotive, Jeep, Truck, UTV, ADV, Dirtbike
• The Scientists of Lighting | Home - Baja Designs - Off-Road LED & Laser Lights | Automotive, Jeep, Truck, UTV, ADV, Dirtbike

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