Warrior 3850 User Manual

Protecting Your Adventure Lifestyle

========================================================================================

QUALITY • INTEGRITY • INNOVATION • SERVICE

Warrior, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone: [phone]
Fax: [phone]

[e-mail]
www.warriorproducts.com

SUBJECT: INSTALLATION INSTRUCTIONS: 3850 FJ Cruiser Folding Pre-Runner Light Bar

1. Begin by removing the 2 torx bolts on the front most mount point of the factory roof rack. Do this on both
sides of the vehicle.

2. Locate the left and right mounting brackets and the hourglass bushings. Press bushings into the mount
brackets carefully. This is done easily with a bench vise or C clamp. WD-40 can make pressing them in
easier as well.

3. Remove the 4 small plastic plugs from the tube on the front of the rack to expose 4 octagonal holes in the
tubing. Using a drill and a sharp 5/8” drill bit, drill the octagonal holes out. Be careful to hold the drill
straight and only drill through the first layer.

4. Push the 4 supplied rubber well nuts into the 5/8”
holes you’ve drilled. They should fit snug in with
the shoulder on the nut being on top of the tube.

5. Identify your left and right brackets by setting them
onto the rack. They should only fit one way. This
photo displays the bracket installed on the
passenger side. Do not bolt them up as you must
first assemble the bar.

6. The light bar itself has dimpled holes across on
one side. This is the front of the bar. With the
brackets identified, slide the brackets onto each
side of the light bar. To slide the bushings over
the studs, it may be helpful to again use WD-40 to
get them installed.

7. It is your choice, but it may be easier to assemble your lights onto the bar before placing the bar onto the
roof. If you prefer to install them before, do so now.

8. With the brackets installed onto the light bar, you can now set the light bar into place on the rubber well
nuts on your roof rack. To do this you will need to spread open the two legs on the roof rack to gain the
space needed to slide the light bar into place. Once you have the light bar into place, use the 5/16” allen
head bolts and 5/16” flat washers supplied to bolt the light bar down. You can now bolt your roof rack
back into place as well.

9. Locate the two 9” struts with threads on each end
and the four ball joint assemblies. Also locate the
included 3/8” fine thread nuts (non-locking).
Thread a nut onto each end of the two struts.
Thread a ball joint onto each end of the two struts.
Thread the ball joints on all the way, and then
adjust them so they are pointing opposite
directions on each end. The end on that will
attach to your strut brackets will point to the
outside of the vehicle and the end that will attach
to your light bar will point to the inside of the
vehicle. Tighten the nuts against the ball joint to
lock them in place.

10. Locate your clam shell brackets, four 5/16” small
flat washers, and three lobed knobs. Assemble
these onto the bar of your roof rack on each side
so that the knobs are on top, and the clamshell
with the extra ear is pointing downward and is on
the inside edge of the rack. As shown in the photo,
you will want to have two washers between the
lobed knob and the clam shell.

Protecting Your Adventure Lifestyle

========================================================================================

QUALITY • INTEGRITY • INNOVATION • SERVICE

Warrior, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone: [phone]
Fax: [phone]

[e-mail]
www.warriorproducts.com

11. Use the 3/8” washers and top lock nuts supplied to bolt the struts to the light bar and to the clam shell
brackets. The photo here is a good reference for steps 9 thru 11.

12. Slide a 3/8” USS (larger) flat washer and locking nut over the studs that mate the light bar to the mount
brackets and tighten.

13. At this point you should have everything assembled. Adjust your light bar angle and tighten clam shells to
secure it into place. Once wired you can adjust aim of the light bar more so to perfect the angle. You can
mark the clam shell location on the bar with tape or a marker for quick reference when folding and
unfolding so that you do not need to re-aim each time.

14. To fold the light bar down, loosen both clam shells and slide them backward as you guide the light bar
down. It does need to have some upward angle to it in order for it to properly lock into place. Once
folded back to a comfortable spot, tighten clamshells to lock into place.

15. Complete your installation by running your wiring. Warrior does not provide wiring instructions for your
light bar. You will need to choose a good location to get wires into the vehicle, most likely through a hole
you will create in the roof. To ease the wiring, Warrior recommends the use of the sPod power distribution
system. Visit http://www.4x4s-pod.com/products/toyota/fj-cruiser for more information.

For more information on Warrior Products Jeep Parts and Accessories, please visit us on the web

at www.warriorproducts.com