JEEP Light Bar Overhead Installation

(This is part of our larger Light Bars for Jeep Guide.)

Pre-Installation

Select the Right Light Bar
  • KC offers three three light bars that can be installed in the overhead or roof configuration on a Jeep. This includes the Gravity Pro6 LED Light Bar, FLEX ERA LED Light Bar, and the Xross Light Bar Mount. Each has a unique set of features and benefits, different sizes, shapes, and light types. Info for each can be found on kchilites.com or via the many informative videos on the KC HiLiTES YouTube channel.
  • Part of selecting the right light bar for your Jeep is ensuring it’s compatible with your year and model. KC offers a host of Jeep-specific overhead light bar mounts. You may always reach out to KC HiLiTES Customer Service at (888) 689-5955 from Monday–Friday 8am–5pm Pacific time with specific questions. 
Gather The Required Tools

Different light bar installations will require different tools. At a minimum, here are the required tools.

  • Metric Wrenches and socket set
  • Torx bits
  • Hex keys
  • Screwdrivers
Optional Tools Depending on Level of Installation

From one install to the next, here are some of the tools that will come in handy if you’re tying the lights into a factory or aftermarket aux switch system:

  • Electrical tape, heat shrink tube, and cable ties
  • Wire strippers
  • Wire crimping tool
  • Heat gun
  • Plastic wire loom
  • Threadlocker, such as Blue Loctite
  • Voltmeter
Safety Precautions
  • Ensure the Jeep is on stable ground with the parking brake engaged.
  • Before installation, disconnect the Jeep’s battery to prevent any electrical shorts.
  • During the installation, wear safety glasses and other personal protective gear when drilling or cutting.

General Installation Process

Preparation
  • Lay out all parts and tools. Ensure all needed parts are present.
  • Carefully read through the installation instructions and familiarize yourself with all the parts and pieces. 
  • KC produces high-quality installation videos and you may find that we’ve already produced one that would be helpful. See the KC HiLiTES YouTube channel for all of our videos.
Mounting Bracket Installation
  • Different Jeep overhead light bar mounting brackets are going to have different instructions and methods. Refer to the product’s included instructions for complete installation details. Note these instructions may also be available on the product’s page under the Downloads & Videos tab.
  • Most KC HiLiTES Light Bar Mounts will not require drilling. However, in universal applications, drilling may be required. 
    • If drilling is needed, mark the spots where you will need to drill holes.
    • Drill any necessary holes carefully, and be sure to wear safety glasses.
  • Following the instructions, remove the specified fasteners from the Jeep, then attach the mounting brackets using the provided hardware, making sure everything is securely fastened.
Light Bar Attachment
  • Place the light bar onto the mounting brackets. Overhead light bars are often larger and heavier, and will require two people to lift into place.
  • Adjust the bar to the desired position and angle. You do not need to aim the light bar yet; simply get it into position.
  • Secure the light bar to the brackets using bolts, lock washers, and nuts. Note: Do not fully tighten at this stage if adjustments are needed.
Electrical Wiring

We recommend viewing our wiring guide page for more information; the below is a general guide.

  • Route the wiring from the light bar to the battery or switch, avoiding hot or moving parts and following the Jeep’s existing wiring paths if possible. We recommend using the Universal Wire Hider to help conceal wires along the Jeep’s A-pillar.
  • Route the wiring from the light bar to the battery or switch, avoiding hot, sharp, or moving parts. Follow the Jeep’s existing wiring paths when possible.
  • Connect the light bar wiring to a switch (most KC lights include a very high-quality switch) if it is not directly wired to an existing wiring harness or auxiliary lighting panel.  This may require running wires into the cab through a grommet in the firewall.
  • Use cable ties to secure the wiring along the way to ensure it does not hang loose. You want the wiring taught and secure.  Trim off the sharp edges of the ties.
  • Attach the ground wire from the light bar to an appropriate grounding point on the Jeep’s frame or body.
  • Connect the power wire to the battery or to a relay if your setup requires it. Again, be sure to follow the instructions with respect to connecting the wires to the battery.
Testing
  • Reconnect the battery if it was disconnected.
  • Power the light bar on to ensure it operates correctly.
  • Make any necessary adjustments to the angle of the light bar. This is a good time to aim the light bar too. Do this in a dark area or during the night time for best results. 
    • Start by having the bar aimed higher than needed. 
    • Move it upwards until it creates a proper beam spread. 
    • Once satisfied with the aim, tighten all the hardware.
    • You may want to bring along an appropriate wrench for your first-night off-road run for any last-minute adjustments.
Finalizing Installation
  • Once everything is positioned and working correctly, secure all hardware.
  • Double-check that all wiring is secure, properly insulated, and correctly routed.  Do one final check for sharp edges that could cut into the wiring in trail conditions.
  • Use electrical tape or shrink wrap and a heat gun to cover any exposed wiring connections.
  • Ensure there is no wire chafing against sharp edges, and use plastic wire loom where needed.
Safety Check
  • Perform a final inspection to make sure everything is tight and secure.
  • Check the lighting once more during nighttime to adjust the beams if necessary.

Product Install Videos

How to Wire Off-Road Lights
Jeep JL & JT Overhead Brackets and Lightbar Install Guide | KC Gravity LED Pro6
Assembling your FLEX ERA® LED Light Bar! | Install Guide
How to Install A-Pillar Light Brackets on a Jeep JL/Gladiator | KC HiLiTES
Jeep TJ Overhead Mounts and Xross Bar System Install

Specific Mounting Solutions for Overhead Light Bars on a Jeep

Post-Installation

Documentation
  • Keep all receipts, warranties, and instructions for future reference.
  • Note any changes made to the vehicle for insurance purposes.
Maintenance Checks
  • Regularly check the light bar for any loosening due to vibration. Using a threadlocker, such as Loctite Blue, can also help reduce the bar from loosening. 
  • Clean the light bar as necessary, ensuring visibility is not impaired by dirt or debris.

Hire an Installer

Not everyone wants to install their Jeep light bar themselves; some would rather leave it to a professional. When hiring a professional to install your KC lights onto your Jeep bumper, it's important to find a reputable and experienced installer who can ensure that the installation is done correctly and safely. Here are some things to look for when hiring a professional to install your off-road lights:

Experience and expertise: Look for an installer who has experience and expertise in installing off-road lights on your type of vehicle. They should be able to provide references and examples of previous installations.  They may even put you in touch with another nearby customer who could show you their installation.

Reputation: Check the installer’s online reviews, ratings, and testimonials to see what previous customers have said about their work. This will give you an idea of their reputation and the quality of their work.

Warranty: Ask if the installer provides a warranty on their work. This will give you peace of mind and protection in case anything goes wrong with the installation.

Price and estimate: Ask for an estimate and compare prices with other installers. Be wary of prices that are significantly lower (or higher) than other installers, as this could be a sign of low-quality work or hidden fees.

When you meet with a potential installer, here are some questions you can ask to determine their experience and expertise:

  • How long have you been installing off-road lights?
  • Have you worked on my type of vehicle before?
  • Can you provide references or examples of previous installations?
  • What kind of warranty do you provide on your work?
  • What is the estimated cost and timeline for the installation?

Finding a reputable and experienced installer for your KC lights is crucial for ensuring that the installation is done correctly and safely. Look for an installer with a good reputation and who provides a warranty on their work. Ask questions to determine their experience and expertise, and compare prices and estimates with other installers to ensure you're getting a fair price.

If you need more information please reach out to [email protected] anytime M-F during work hours. Remember, these are general steps, and your specific product or vehicle might require different procedures. Always refer to the manufacturer’s instructions for the best results, and consider professional installation if you are not confident in doing it yourself.

About the Author

Andy Lilienthal is a freelance writer who specializes in all things automotive. He has written professionally since 2001 and continues to freelance. His works include writing and photography for a host of publications ranging from off-road print magazines, to new-car reviews online. Andy is also a photographer who has had images in multiple magazines, blog sites, and the New York Times. His automotive knowledge has made him a SME (subject matter expert) on many things automotive, and he has appeared in the New York Times, on APM Marketplace, and multiple other publications with regards to automotive.

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