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How to Install Carr XRS Rota Light Bar - Black (97-06 Wrangler TJ) on your Jeep Wrangler
Installation Time
1.5 hours
Tools Required
- T40 Torqx Bit and Ratchet
- Blue Thread Locker, (Serviceable)
- ½” Wrench
- WD-40 or equivalent
Note: Have a second person available for the actual mounting of the light bar to your Jeep TJ. It may be easier to mount your lights prior to mounting the light bar on the Jeep.
Installation Instructions:
1. Layout and check all parts. Read the instructions fully before starting assembly.
2. Insert the rubber grommet on both light bar side mounts. Lubricate with WD-40 to allow easier insertion. Use a twisting motion will applying pressure until it pops into position.
3. Make sure grommet is fully inserted with the large side facing to the outside.
4. Using a rotary tool, clear the power coat paint from the inside of the Rota Hood Casting. The welded nut MUST fit inside the Rota Hood Casting sitting flush.
5. Assemble the Rota Hood Casting, Rota Square Casting and the Welded Nut using the 3/8” bolt. Tighten fully, then loosen by a ½ to 1 full turn. This will be fully tightened later. Repeat for other side.
7. Apply Serviceable Thread Locker, (blue) to 8 - ¼” bolts. Using these bolts and nylon washers secure the Rota Square Casting assembly to the side mounts. Repeat for the other side.
8. Insert the Cross Bar into the Rota Hood Casting. Secure using a 5/16” bolt inserted from the top and the double hole washer and nylon locking nut. Repeat for the other side. The bar is complete and ready to mount.
9. With the light bar complete, it is a good time to mount your lights. See your lights instructions for the mounting directions.
10. Remove the three bolts from the windshield hinge on one side.
11. While a second person holds the opposite side, Using 5/16” X 1 ½” bolts with serviceable thread locker applied, and 5/16” washers, mount the light bar and snug up the bolts. Make sure the mount does not interfere door opening / closing. Repeat for the other side.
12. With the light bar mounting complete, Level the bar rotation to the desired angle and secure the 3/8” bolt on both ends of the light bar.
Written by ExtremeTerrain customer Tim Russell, 09/30/2017
