TJ LED Conversion
Page 4
Use masking tape for marking the spots where the holes need to be drilled, this will aid later when painting the freshly cut holes. For the 4 S/T/T mark up (this is for both sides of the tub) 11-3/8 and over from the corner of the tailgate 6-1/8. This position will allow you to remove the stock mounting holes, it also allows there to be some sheet metal for centering the hole saw. The biggest hole saw my hardware store had was a 4-1/4, the hole needs to be 4-5/16 for a 4 LED. This means you will have to cut the hole and then file or grind to 4-5/16, the alternative method of using a jig saw can be used also. The license plate hole is 10 up and 2-3/4 over. Remember I said, this was not where I wanted it? If you go 3/8 over to the right and Ύ down you will be fine. This will put the center hole at 9-1/4 up and 2-3/8 over, you need to drill a 1-7/8 hole here. There are two mounting screws for this license light that need to be drill also, mark them after the large hole is drilled use the light for a template then use an 3/32 drill bit. Put the light in place hold the light horizontal for marking.
Now to the marker light, using tape again, mark 8 up and 2-1/8 over from the seem of the tub. Use a 2-5/16 hole saw to cut this hole (disregard the picture saying 2-3/8) do this to both sides of the tub. The holes cut need to have paint on them, I also used some silicone between the grommets and the tub (do not silicone the lights to the grommets) right before inserting them into the holes, I hate rust. Once this is done it is time to start the install for the harnesses. The hardest part about this hole job is finding a spot to connect the ground. With the holes drill for the large LEDs drilled you can get a drill motor inside the corner compartment through the hole and make a hole for a grounding screw on the ledge inside. It is a tight fit but, can be done. If you have some other place to connect the ground or can think of something better, go for it.
Plug the harness
into the existing wiring harness apply silicone grease. The left side you will
have to plug in the license plate light also and install the two screws that
hold this light in place. Run the reverse light down through the bottom of the
tub and through the bumper and plug them in. USE SILICONE GREASE, I cannot
emphasize
this enough. The picture shows a packet of this grease it is about a dollar for
this packet you will not even use one, it is well worth it. Put the marker light
grommet in place and hook up the harness to the marker light then push the light
into the grommet. Next put the large grommet in and pull the wires through it
and plug the large light in. This would be a good time to make sure all is going
well with the install. Turn on the running lights and the emergency flashers. If
you want to you can set the emergency brake, put the vehicle in reverse and
check the reverse lights.