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  1994 - 2004 Ford Mustang Light Bar Installation Instructions
   

Availability: Now In Stock
Installation Time: 2 Hours

 

Tools Needed: Parts included in Package:
1/4" Drive Ratchet Pop Rivet Tool
1/4" Drive 3" Extension Drill Motor
1/4" Drive 10mm Socket Drill Bits 1/8", 19/64" *, 13/32" *
1/4" Drive 7mm Socket 3/4" Hole Saw
T-25 Torx Bit 1" Hole Saw
3/8" Drive Ratchet 1 3/4" Hole Saw
3/8" Drive 3" Extension Door Trim Tool (Fork Tool)
T-50 Torx Bit Center Punch
1/4" Allen Wrench Hammer
Wire Crimper Putty Knife

* 99 up models for seat belt loop modifications

Kit Components:

  • 1 - Light Bar

  • 4 -  Ply Plugs

  • 4 - 94 Light Bar Bolts

  • 4 - 94 Light Bar Washers

  • 2 - 94 Light Bar Rivets

  • 2 - Light Blue Connectors

  • 2 - Dark Blue Connectors

  • 1 - Left Bar Brackets

  • 1 - Right Bar Brackets

1. Remove back seat.

    A) A spring-loaded retainer holds the lower seat cushion.  The cushion is released by locating the retainer that is approximately 10 inches from the edge of the cushion on either side.  Take a flat screwdriver and push in retainer release button.  The seat should pop up and be released.

    B.) The back seat cushion is held by two 10mm screws, located on each lower corner. Remove screws and slide seat upward releasing cushion from bracket at the top

2. Remove Side Quarter Trim Panels

    A.)  Remove upper speaker grille (or dummy cover) and "T" trim between speaker opening and shoulder belt opening.

    B.)  Remove retaining pushpin at convertible top well at the back edge of the trim panel

    C.)  Remove the two small pins holding rubber seal to front upper edge of trim panel.

    D.)  Remove rocker sill covers starting at the front pulling upward working to rear.

    E.)  Remove the two pushpins aligned vertically behind seat back.

    F.)  For 94-98 Models - Firmly grasp quarter trim panel and pull panel forward to dislodge the two retaining clips along front inside wall of the trim panel.

    G.)  With panel loose, lean panels to access the "torx" head bolt that retains the seat belt retractor and remove it.

    H.)  For 99 & Up Models - Remove "torx" head bolt holding end of seat belt to vehicle

   I.)  Slide seat belt end/retractor through panel and remove trim panels from vehicle.

3. Remove Speakers

    A.) Remove two 7mm screws from speaker mounts (one in the door jam and one at the top), lay speakers out of the way.

4. Loosen Inner Quarter Covers

    A.) Pull plastic quarter covers loose from vehicle by prying with a putty knife. They are held by two pins and body sealer/caulk.

5. Locate and Mount Light Bar Brackets

   A.) Use the right side bracket (marked with an "R") to mark the left side of vehicle.  Place the bracket against the sheet metal of vehicle to the inside of body seam with crimp nut facing to front of car, line up the small 1/8" hole with the small hole on the car.  (The hole is not used on a car with Mach 460 Stereo systems and is used with the standard stereo for mounting speaker bracket).  Use the 1/8" rivet supplied in kit, for lining up the holes, and then line the brackets to run parallel with the edge of the "B" pillar hold in place and center punch through nuts on bracket. (See diagram 5)

   B.) Next, drill center punched marks with a small 1/8" drill bit, then enlarge holes with a ¾" hole saw, this will keep your hole centered.

   C.) Mount your brackets behind "B" pillar by reaching bracket through quarter opening, a lining small hole through "B" pillar into hole in bracket with pop rivet provided.  Then rivet into place.  The holes you drilled should line up with bracket.

NOTE:  Crimp nut on brackets MUST face rear of vehicle for proper assembly.bar will not tighten correctly if reversed

Re-stick quarter cover into place and remount speakers, cars with standard stereo will need to trim speaker mount form obstruction light bar bracket hole.

6. Laying out holes in trim panel

A.) With a putty knife, remove the upper mounting clip.  Using the template provided, carefully layout template and tape in place.  Then with the 1/8" drill bit, drill center of holes, marked on template.  Repeat for other side.

7. Drill trim panel holes

A .) With a 1 ¾" hole-saw drill the 1/8" hole on the top side of the trim panel, the two holes should intersect.  After drilling, file the center making the hole a long oval.

 B.) Now with a 1" hole-saw drill, from the backside, the two 1/8" holes in front of the trim panel.

8. Reinstall trim panels

    A.) Reinstall both trim panels by reversing step 2.

9. Placement of Classic Light Bar

    A.) Line up Classic light bar with top holes in trim panel.  Guide your brake light wire through trim panel.  Evenly lower classic light bar into holes.  You may have to ask for assistance to push the bar inward while lowering.

10. Bolting the Classic Light Bar -

    A.) Using bolts provided, line up classic light bar with nuts in bracket. You may have to push or pull bar to line it up. Leaving bolts loose put all four bolts in, then push bar down so base of bar is flush with trim panel and tighten bolts.

11. Bolt covers

     A.) There are four caps provided, push them into holes in trim panel, covering bolts.

12. Connecting the brake light

 ( Note: Wiring difference for 1999 and up )

     A.) Now that the bar is in the car and bolted down, you will need to connect the wires for the brake light.  You will find the main wiring harness on the driver-side rear seat area, it is a long rectangular box.  After cutting away the black tape, pull out the wires from the box.  You will need to find a red wire with a green stripe ( Solid Green for 1999 & up ) and a solid black wire.  Using the two dark blue connectors, tap into each wire.  Then using the light blue connectors, crimp those to the wire from the light bar.  Plug that into the dark blue connectors.  Test the brake light by depressing brake pedal.  If the light does not work, reverse your connections.

13. Reinstall your back seat

    A.) Reinstall by reversing step one.

Step 1:  A spring-loaded retainer holds the lower seat cushion.  The cushion is released locating the retainer that is approximately 10 inches from the edge of the cushion either side.   Take a flat screwdriver and push the side of the retainer.  The seat should pop up and be released.  Two 10mm screws hold the back seats cushion located on each lower corner.  Remove the screws and slide seat upward releasing cushion from bracket at the top.

14. Checking Belt Clearance after Light Bar is installed

Once the light bar is installed, check the seat belt clearance on the driver seat and passenger seat in the full upright position and each consecutive position back.  If the seat belt retainer is hitting the bar, gently bend retainer down.  Failure to do so could result in the damage to the light bars vinyl finish.  CDC will not be responsible for any damage that may occur if this step was not taken.

1994-2004 Models SEE ATTACHED BULLETIN

 We hope you enjoy motoring with your new classic light bar! The classic light bar is NOT intended to protect in case of a rollover.

Patented all rights reserved by Classic Design Concepts, Inc.

NOTE: 1999  & UP Mustang Bulletin

Due to the larger size of the seat belt shoulder loop on the 1999 Mustang, modifications to this loop is necessary or the purchase of new loop is recommended Seat Belt retainer bracket PART # (Left) - F4ZZ 76610C07 A   (Right)f4ZZ 76610CO6 A

Modifications Instructions

  1. Lift headrest and headrest support bars trim all the way up.

  2. Insert wood stick (or slim jim) down the front side of the headrest bar.  Push stick down as far as possible .  When the stick is beneath the headrest trim piece, and push headrest all of the way down.

  3. Remove headrest

  4. Bend seat belt shoulder strap loop down so that the leg that attaches under headrest is flat

  5. Remove seatbelt loop and torx bit.

  6. With template shown below, center punch for new holes and mark for cut off.

  7. Drill 1/8" Pilot holes

  8. Drill 13/32" hole in plastic only (on topside only)

  9. Drill 19/64" hole through remaining material

  10. Cut off end on new cut off line mark

  11. Clean off any burs and re-install




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