How to Install a KC Hilites Black Overhead Light Bar on your 1997-2006 Jeep Wrangler TJ

Thanks for choosing a KC HiLiTES product. We take pride in building the highest quality, best engineered systems possible. Your satisfaction with our product is important, so if you have any questions, please call our customer service line at 800-528-0950 or 928-635-2607.

1 - Center Cross Bar w/4 Tabs
2 - Support Brackets (left & right) 
2 - Plastic End Caps 
1 - 5/16” x 1 1/4” Set Screw 
6 - 5/16” x 1 1/4” Allen Head Bolts
2 - 5/16” x 1” Hex Head Bolt 
2 - 5/16” Flat washers
2 - 5/16” Lock Washers

NOTE - We recommend using a light duty LOCTITE on all windshield bracket mounting bolts.

1. Beginning on the driver’s side, remove the center factory torx head bolt from the side of the upper windshield hinge bracket. Insert the supplied set screw temporarily in its place. This will ensure the plate inside does not get out of alignment. Now remove the remaining three bolts (two on the side and one on the front).

2. Place the driver’s side light bar support bracket in position on the windshield hinge over the set screw already in place. Hand tighten one of the 5/16 Allen head bolts in both the upper and lower bracket holes. Remove the set screw and loosely fasten the other Allen head bolt. Now hand tighten one of the hex bolts, flat and lock washers to the front of the support bracket.

3. Lubricate both ends of the center bar with a multi-purpose grease. THE KNOBS ARE PREASSEMBLED AND SHOULD NOT BE REMOVED FROM THE BAR. With light tabs aimed upward, align the slot in the center bar with the threaded part of the knob on the inside of the support bracket. (Fig. 1) Slide into place and turn center bar counterclockwise until light tabs are level. Tighten knob to secure.
(Do not over tighten)

4. Repeat the procedure on the passenger side ensuring that you slide the passenger side mounting support bracket onto the center bar before attaching to the windshield hinge.

​DO NOT FULLY TIGHTEN ANY BOLTS AT THIS TIME

5. After ensuring all parts are in alignment, you may now tighten all bolts and knobs. Check all bolts for tightness after the first 500 miles of use.

If necessary, you may rotate the center bar forward for less wind resistance or clearance to enter your garage. Simply loosen the two knobs slightly and rotate the bar and lights forward. Re-tighten the knobs.

You’re DONE! - - - - - - - Install your KC lights and enjoy.

​IF YOU HAVE ANY PROBLEMS OR QUESTIONS, PLEASE CALL CUSTOMER SERVICE AT 800-528-0950