This is the open end of the Mounting
5/16" Bolt
Mounting End Castings
Tinnerman Nut
LIGHT BAR MOUNTING INSTRUCTIONS
Part No’s: 210441, 210442 & 210444
Cross Bar
Windshield
Split Lock Washer
1/4" Bolt
Drill motor, 5/16” drill bit, hammer, center punch, ½”
drill bit, hacksaw.
MATERIALS FURNISHED: One hardware pack, two end castings, cross bar,
instruction page.
Bend Rubber Gasket
THIS LIGHT BAR FITS THE FOLLOWING VEHICLES:
JEEP
‘76 – ‘95 Jeep CJ/YJ Wrangler
WARNING!
THIS CARR LIGHT BAR IS DESIGNED TO HANDLE A TOTAL
WEIGHT OF FOUR (4) LBS. ANY ADDITIONAL WEIGHT
BEYOND THIS CAPACITY, MAY RESULT IN SERIOUS
DAMAGE TO YOUR VEHICLE AND/OR ANOTHER VEHICLE.
End Casting. Measure from this point
on each Mounting End Casting.
(See step 11 on the L
Instruction)
Quality and Style that Endures
Follow the diagram and the written
directions carefully for a proper,
safe installation.
Should you encounter an unusual,
unforeseen problem, contact our
Technical Help Line
7:00 AM – 3:00 PM Pacific Time
(951) 719-1068
Visit our web-site at
www.CARR.com
Carr Pattern Co., Inc.
this could result in an oblong or oversized hole. If you do not think you
frame, using the holes in the castings
LIGHT BAR MOUNTING INSTRUCTIONS
of paint will result. Remove the PVC tape from the brackets (does not apply to black brackets). The light bar will not
unless the bar is straight across the cab.
Part No’s: 210441, 210442 & 210444
Do not over tighten the nuts and bolts or damage to the castings and or stripping of the threads could result.
FOR SAFE AND PROPER USAGE OF THIS PRODUCT, THE MOUNTING INSTRUCTIONS MUST BE FOLLOWED CAREFULLY AND COMPLETELY.
The manufacturer and distributor of this product are in no way responsible for the consumer’s failure to adhere to the warnings and directions of these instructions in the event of damage to the
consumer’s vehicle, other properties and or personal injury.
DO NOT REMOVE the PVC tape from the light bar until cutting is completed. When cutting black bar leave plastic bag on and wrap a rag around bar before putting into a vise so no scratching
WARNINGS!
1. Line up the holes in the Mounting End Casting and the rubber gasket, hold in position on the windshield frame, and mark the two side holes on the
windshield frame with a pencil. IMPORTANT: when positioning end casting on the windshield frame, make sure it is up against the flat part of the
frame, not a curved section. Also, make sure the end bracket will not interfere with the opening and closing of the door or the removal of a soft top.
2. Follow the same procedure for the other side. IMPORTANT: To ensure that the light bar is level, measure up the exact same distance from the
windshield frame hinge to the bottom of the second end casting.
3. Center punch the two marked side holes on each side of the windshield frame from step 1.
4. Take a sharp 5/16" drill bit and drill out the four center punched holes. Then go back and enlarge the four holes to ½". WARNING: For best results the
½" holes should be drilled to size. DO NOT drill the holes oversize and or oblong. A new ½" drill bit will make this task more accurate. AVOID
drilling holes at an angle. Avoid forcing or pushing too hard on the drill motor can drill these holes precisely, consider taking your vehicle and light bar to a professional installer. This warning applies to steps 7 and 8 as well.
5. Take Tinnerman nuts provided and tap them into the holes you have drilled, with the flange flat against the window frame metal.
6. Using the 1/4" tamper-proof Allen head bolts, 1/4" split-lock washers, and 1/4" flat washers, take one end casting with rubber gasket, and mount to
windshield frame. Securely tighten with Allen wrench provided. Repeat for other side.
7. With both castings securely mounted to the windshield frame, drill 5/16" holes through the front of the windshield
as a guide. Then remove both castings.
8. Drill out the two 5/16" holes to ½". Tap in a Tinnerman nut in each front drilled hole.
9. Re-mount both end castings with the hardware provided. Mount the two sets of outside bolts and securely tighten them first. Then securely tighten the
two front bolts.
10. Remove any excess rubber gasket for a cleaner appearance.
11. With Mounting End Brackets installed, take a tape measure and measure the distance between each open end of each Mounting End Casting (refer to
diagram).
12. Add 2 inches to that dimension.
13. Subtract that total from the total length of the bar, which is 56".
14. Take the difference and divide it by two.
15. The amount divided by two is the amount you will cut off each end of your bar. CAUTION: Do not cut off one end, the lights will be off center.
16. Measure and mark a line on both ends of the steel bar using the dimensions from steps 11-15.
17. Clamp the end of the bar into a vise (be careful not to scar the light bar). Using a hack saw, cut carefully along the lines you have marked. If a vise is
not available, put the bar on a table or bench, securely tighten, and cut. IMPORTANT: For black and silver-titanium bars, paint the cut surfaces of the
bar with rust-resistant paint.
18. Remove PVC tape or plastic bag from light bar. Place bar underneath Mounting End Castings and push into place. Be sure bar is centered.
19. Put a 5/16" Allen head bolt through top of each Mounting End Bracket from the top down.
20. Place large rectangular washers inside of bar. Push the light bar up inside of each Mounting End Bracket. IMPORTANT: Be sure that the rectangular
washers are completely underneath the Mounting End Brackets.)
21. With rectangular washers in place, take nylon lock nuts and Allen wrench provided, and securely tighten the light bar to the end castings.
22. The light bar mounting bolts that attach to the windshield frame should be checked periodically and tightened if necessary.
23. Check again and securely tighten ALL hardware
24. After one month of use, go back and give all hardware a final tightening.
25.
To maintain luster of polished areas use an aluminum polish on a regular basis.
Finishes: Limited Lifetime
Structural Warranty: Limited Lifetime
Warranty Conditions:
a. All warranties start from consumer’s date of purchase.
b. A new product will be sent out immediately to replace a warranty claim.
c. The above guidelines apply only to the Original Purchaser.
d. Original proof of purchase must be submitted for all warranty and returns issues.
Warranty Limitations:
a. Warranty coverage extends ONLY to repair or replacement of the CARR product. This warranty does not cover the cost of labor, transportation, installation or removal of the product.
b. Warranty coverage does not extend to damage caused by: collision, fire, theft, freezing, vandalism, riot, explosion or object striking the product, or misuse of the product and/or the vehicle on
which the product is being installed.
c. Warranty coverage does not extend to damage caused by: airborne fallout (chemicals, tree sap, etc.), stones, hail, earthquake, water or flood, windstorm, lightning, the application of chemicals or
sealants subsequent to manufacture.
d. Warranty coverage does not extend to damages caused by: normal wear and tear, abuse, modification or improper installation of the product.
e. Warranty coverage does not extend to any economic loss or extra expense including (without limitation), payment for the loss of time or pay, inconvenience, storage, loss of vehicle use, vehicle
rental expense, equipment rental expense, lodging, meals, or other travel costs.
Other Terms:
This warranty gives you specific legal rights and you may also have other rights that vary from state to state. CARR does not authorize any person to create for it any other obligation or liability in
connection with its products. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE APPLICABLE TO THIS PRODUCT IS LIMITED IN
DURATION TO THE DURATION OF THIS WRITTEN WARRANTY. PERFORMANCE OF REPAIRS AND NEEDED ADJUSTMENTS IS THE EXCULSIVE REMEDY UNDER THIS
WRITTEN WARRANTY OR ANY IMPLIED WARRANTY. CARR SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM BREACH OF
THIS WRITTEN WARRANTY.*
*Some states do not allow limitations on how long an implied warranty will last or the exclusion or limitation of incidental or consequential damages, so that above limitations or exclusions may not
apply to you.
Guarantee: Every attempt has been made to manufacture and distribute the finest quality products available. Our manufactured products are guaranteed to be free of defects due to workmanship or
materials. Distributed products are subject to manufacturer’s warranty only.
CARR ● 27447 Bostik Court ● Temecula CA 92590
Warranty Policy