TRX-4 Sport Complete LED Light Kit Installation

2617
2.5x8 BCS
2617
2.5x8 BCS
2617
2.5x8 BCS
2617
2.5x8 BCS
2617
2.5x8 BCS
2.5x10 BCS*
2.5x10 BCS*
3965
2.5x8 CS
3965
2.5x8 CS
3965
2.5x8 CS
3965
2.5x8 CS
3965
2.5x8 CS
2617
2.5x8 BCS
B
A
F
C
D
E
F
G
I
J
J
H
K
C
I
J
Tip: If you have a rotary tool (such as Dremel®), then use a small routing bit to
cut out the openings. Start by using the tapered reamer to make a small hole
inside the area to be removed. Insert the routing bit into the hole, and then
follow the cut out lines. CAUTION: Wear your eye protection when using the
motorized tool! Use a hobby knife or a small file to carefully trim the corners
square. When using a hobby knife, score the body material several times with
the knife blade, and then snap it over to break and release. This will provide the
cleanest cuts. Do not try to cut all the way through the body material in one
pass or “saw” it with the knife blade.
4. Using a body reamer, cut a small hole in the front left corner of the roof
of the truck body for the LED roof light bar. The hole needs to be large
enough to pass the connector for the light bar through the body. Note: It
is important to cut the hole in the correct location or the light bar will not
mount correctly (see Wiring Diagram, Fig. 6).
5. Using a hobby knife or rotary tool, cut a slot in the front left corner of the
truck bed for the expedition rack scene lights. The slot needs to be large
enough for the harness connector to pass through (see Wiring Diagram, Fig. 6).
LED Light Installation
Note: While installing the LED lights, install the included zip tie mounts and
use zip ties to secure the wiring to the body in the locations provided. The zip
ties do not need to be tight; allow some slack for wire movement.
1. Install the front grille (A) with the front grille retainer (B), headlight clamps
(C), tailgate panel (D) with the tailgate panel retainer (E), and tail light clamps
(F) on the truck body using the included hardware.
2. Install the LED light kits; refer to the Assembly Diagram (Fig. 5) and Wiring
Diagram (Fig. 6). The headlights (G) and tail lights (H) snap into the receptacles
of the headlight clamps and tail light clamps.
Note: Installation of the roof LED light bar (I) and/or scene lights (J) requires
the TRX-4 Expedition Rack Kit (K) (part #8120 or #8120X, sold separately).
3. Secure the roof light bar to the expedition rack using the 2.5x8mm cap
screws (2). Secure the scene lights (4) to the expedition rack using the
2.5x8mm cap screws (8). The expedition rack scene lights install as an
assembly using the hardware provided. When installing the scene lights,
note where the light string begins and ends in the Wiring Diagram. Do not
overtighten the screws that fasten the scene lights to the expedition rack.
Hand tighten these screws. Feed the connectors through the holes in the
body; then, install the expedition rack on the vehicle body according to
the kit instructions.
Distribution Block Installation
1. Install the distribution block (L) on the tailgate panel retainer and secure it
with the 2.6x8 mm button-head screws (2) as shown in Fig. 4.
2. Plug the connectors from the LED light wire harnesses into the ports of the
distribution block. Match the color band on the wire harnesses with the
corresponding color of each port indicator on the distribution block (white for
the headlights, red for the tail lights, yellow for the roof LED light bar or the
expedition rack scene lights).
3. Plug the included jumper into the green port of the distribution block.
Note: The jumper will allow the LED lights to go into full power (high beam)
mode. The jumper is not required for the LED lights to function (the lights
will remain in low power (low beam) mode if the jumper is not used).
4. The 4-in-2 wire harness (part #8089, sold separately) is required when installing
both the roof LED light bar and the expedition rack scene light kit. Plug the
roof LED light bar and scene lights into the 4-in-2 wire harness; then, plug the
harness into the yellow and green ports on the distribution block.
Assembly Diagram
Fig. 5
2.6x8 BCS
Fig. 4
L
Rear Tailgate
(looking inside of the
vehicle body)
*Only use the 2.5x10 BCS if installing the #8084 or #8085 LED light kits.