ROUSH Convertible Light Bar Kit
ROUSH Convertible Light Bar Kit
P/N R08060001, R08060008, R080600010
Application: 2005 - 2010 Convertible Ford Mustang
Important Note: This Light Bar is not intended to be used as a Roll Bar and will
not provide any protection in the event of a roll-over accident.
Installation Instructions
Before installing your ROUSH Performance Product(s), read through the entire
installation procedure and check to make sure all items are present. Contact ROUSH
Customer Service at 1-800-59-ROUSH, weekdays from 9:00 AM to 5:00 PM EST, with
any questions regarding fit, missing parts or instructions that are unclear to you.
Packaging List for Complete Light Bar Kit
Item
Convertible Light Bar
Part No.
R08060002 (Charcoal)
R08060009 (Dove Gray)
R08060011 (Camel)
Driver Side Bracket w/Set Screw
R08060003
Passenger Side Bracket w/Set Screw R08060004
Wiring Harness
R08060005
Hardware Kit
R08060006
Button Head Bolt
Flange Nut
Template
R08060012
Installation Instructions
R08060007
Quantity
1
1
1
1
1
4
4
1
1
Convertible Light Bar
(Wire Harness may be stuffed into tube
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Driver Side Bracket #R08060003
Passenger Side Bracket #R08060004
Hardware Kit #R08060006
Wiring Harness #R08060005
Instructions and Template
Equipment and Supplies Required
⅜” Drive Ratchet
⅜” Drive 3” Extension
⅜” Drive 10mm Socket
⅜” Drive 13mm Socket
T-50 Torx Bit
Trim Tool (Fork Tool)
Heat Gun (or similar heat source)
¼” Allen Wrench (4” long, ball-ended recommended)
Center Punch
½” Wrench
Solder
Solder Iron
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Drill Motor
⅛” Drill Bit
5/16” Drill Bit
2” Hole Saw
T-20 Torx Bit
Wire Crimpers
Wire Strippers/Cutters
3/ ” Allen Wrench
16
Hammer
Shop Vacuum
Electrical Tape
1-800-59-ROUSH
LIMIT OF LIABILITY STATEMENT
The information contained in this publication was accurate and in effect at the time the
publication was approved for printing and is subject to change without notice or liability.
ROUSH Performance Products (RPP) reserves the right to revise the information presented
herein or to discontinue the production of parts described at any time.
SAFETY REQUIREMENTS
STOP! READ IMPORTANT SAFETY CAUTIONS AND WARNINGS BEFORE
PROCEEDING.
IMPORTANT SAFETY NOTICE
Appropriate disassembly, assembly methods and procedures are essential to ensure the
personal safety of the individual performing the kit installation. Improper installation due
to the failure to correctly follow these instructions could cause personal injury or death.
Read each step of the installation manual carefully before starting the actual installation.
1.
2.
3.
4.
5.
Always wear safety glasses for eye protection.
Place ignition switch in the OFF position.
Always apply the parking brake when working on a vehicle.
Block the front and rear tire surface to prevent unexpected vehicle movement.
If working without a lift, always consult vehicle manual for correct lifting
specifications.
6. Operate the engine only in well-ventilated areas to avoid exposure to carbon
monoxide.
7. Do not smoke or use flammable items near or around the fuel system.
8. Use chemicals and cleaners in well-ventilated areas.
9. Batteries produce explosive gases, which can cause personal injury. Therefore,
do not allow flames, sparks or flammable substances to come near the battery.
10. Keeps hands and any other objects away from the radiator fan blades.
11. Keep yourself and your clothing away from moving parts when the engine is
running.
12. Do not wear loose clothing or jewelry that can get caught in rotating parts or
scratch surface finishes.
13. Allow the engine, cooling system, brakes and exhaust to cool before working on
a vehicle.
WORK SAFELY!
Perform this installation on a good clean level surface for maximum safety and with
the engine turned off.
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1.
Remove Back Seat:
A) Locate the retainers securing the
seat bottom into the vehicle,
approximately 10 inches from the
end of the cushion, either side.
Use your thumb to push in
retainer release tab. Lift the seat
up to remove. Refer to Figure 1.
Figure 1
B) Remove the two 13mm screws
securing the seat back, located on
each lower corner. Lift seat
upward to release seat back from
brackets at the top. You can
carefully prop the seat back under
the retracted top. Refer to Figure
2. Use caution if choosing this
method not to damage or scratch
the vinyl of the seat. You can
remove the seat from the vehicle
completely by disengaging the
flanges securing the top of the
rear seat to the fabric of the
convertible top well. Refer to
Figure 3.
Figure 2
Figure 3
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2. Remove Quarter Trim Panels:
A) Grip the Quarter Trim Panel Cap
at the shoulder strap opening and
lift up to dislodge the retaining
clips. Refer to Figure 4.
Figure 4
B) The inside Quarter Trim Panels
are two-piece panels. Remove the
upper portion of the Quarter Trim
Panel from the vehicle; it is not
necessary to remove the lower
portion. Pull the forward edge of
the trim Panel over the pinch weld
in the doorjamb. Use a Door Trim
Tool (Fork Tool) to dislodge the
pushpin retainer at the rear edge
of the Trim Panel approximately
4” down from the top, pry Trim
Panel toward the outside of car to
release retainer. Refer to Figure 5.
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Figure 5
1-800-59-ROUSH
C) Use a Door Trim Tool (Fork Tool)
to dislodge the pushpin retainer at
the rear edge of the Trim Panel
approximately 4” down from the
top, pry Trim Panel toward the
outside of car to release retainer.
Refer to Figures 6 & 7.
Figure 6
Figure 7
3. Install Light Bar Brackets:
A) Remove the shoulder belt guide
retaining bolt with a T-50 Torx Bit.
Remove the 10mm head bolt directly
behind the shoulder belt guide. Refer
to Figure 8.
Figure 8
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B) Install the Light Bar Bracket to the vehicle
using the factory bolts removed in the above
step. Refer to Figure 9.
Figure 9
Note: It is imperative that the shoulder strap guide bolt spacer fit inside of the
clearance hole of the Light Bar Bracket so that the seat belt functions properly and the
Light Bar Bracket fits properly.
Note: Torque seat belt guide bolt (T-50 Torx) to 30lb-ft.
C) Remove the four (4) Speaker fasteners with a T-20 Torx bit and remove the speaker.
Move speaker away from the general area to keep drill shavings from sticking to the
speaker magnet.
D) Remove the belt retractor retaining bolt
with a T-50 Torx bit. Refer to Figure 10.
Lift up on the base of the retractor and
detach top hook. Place retractor out of
way of any debris.
Figure 10
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E) With the Light Bar Bracket in
place and secured by the 10mm
head bolt and the shoulder strap
guide bolt reinstalled and tight,
center punch through the two
Bracket attachment holes. Drill
⅛” pilot holes through Bracket
hole into sheet metal. Enlarge
pilot holes to 5/16”. Refer to
Figure 11.
Figure 11
Note: It is very important that you protect the Seat Belt and the Shoulder Strap
Retractor from the cutting debris that is created during the drilling process. We
recommend using a Rag to cover the Retractor to keep debris out of the mechanism
during drilling.
F) Using the Shop Vac, vacuum up any metal shavings.
G) Reinstall belt retractor and torque T-50 Torx fastener to 30 lb-ft.
H) Install the Button Head Screws
through the Bracket, securing
Bracket to the vehicle, and tighten
to 18 lb-ft. Refer to Figure 12.
Figure 12
I) Reinstall the Drivers Side upper portion of the Quarter Trim Panel. Install only the
pushpin retainer portion or the Passenger Side Quarter Trim Panel.
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4. Cutting holes in Quarter Trim Panel Caps:
A) Cutout the Template (supplied in kit) and place on the Passenger Side Trim Panel Cap
and align as directed on the Template. Refer to Figure 13. Center punch the 2” hole
center point, remove the template and drill an ⅛” pilot hole. Follow in the pilot hole
with a 2” Hole Saw.
B) Flip the Template over and place on the Driver Side Trim Panel Cap and repeat the
above steps for marking and drilling the 2” hole.
Figure 13
5. Reinstall Quarter Trim Panel Caps:
Install the Drivers side Trim Panel Cap and loosely install the passenger side Cap (do not fully clip
into place). Verify that the 2” holes drilled in step #4 do not obstruct the Light Bar Bracket receiver
tube. If the receiver tube is blocked, trim the Cap as necessary to achieve an unobstructed path
for the Light Bar to install into.
6. General Wire De-pinning Procedure
Note: The directions and pictures in the following are for illustration only and do not
exactly represent any of the exact connectors that are part of this procedure. Use
extreme care when trying to de-pin a wire, the process does not require very much
force. If too much force is applied, the locking tab will break. Without a functioning
locking tab, there will be no way to retain the wire/pin in the connector body and it
will pull/vibrate out of the connector.
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A) Verify that the correct wire and cavity
location have been chosen. Refer to
Figure 14.
Connector with
Cavity #s
highlighted for
clarity
Figure 14
B) Remove the locking insert by lifting its
tab from both sides of the connector
body. Refer to Figures 15 & 16. Slide
forward until both are fully into the
body of the connector. Using a pick
tool or paper clip, lift the locking
insert out of the face of the
connector. Refer to Figure 17.
Locking Tab
(white)
Same for both
sides
Figure 15
Lifting Locking Insert
out of connector
Connector with Locking Insert fingers
lifted out (bent out for clarity only).
Push forward from here.
Figure 16
Figure 17
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C) Holding a very slight tension on the wire you intend to remove, insert a pick tool or paper
clip down into the face of the connector and slide it down the edge of the pin you want to
release. Carefully slide the pick/clip between the pin and the locking tab and lift the tab
and pull the Pin out of the bottom of the connector. Refer to Figure 18.
Cutaway View
Figure 18
Hint: If using a paper clip or similar to remove the pin, sharpening the tip to a
point will help you get the tip under the locking pin easier.
D) Install new pin/wire by gently inserting the pin into the bottom of the connector in the proper
orientation (will only slide in properly in one orientation) and sliding it in until it clicks into place
and cannot be pulled back out. Replace the locking insert.
7. Install Center High Mount Stop Lamp (CHMSL) Wiring
Wire Harness Installation Notes: The 2010 Mustang has wire harness changes that affect the
installation of the Roush Light Bar Wiring Harness. The 10 way connector, in the trunk, which was
used as the source of the CHMSL circuit on 05-09 models, is not available.
The CHMSL circuit, on the 2010 Mustang, originates at the Body Control Module (cavity 18) and is
a single Yellow/Gray wire to the CHMSL. In order to connect to the CHMSL circuit, the Yellow/Gray
wire must be located and the Light Bar Wire Harness spliced to it.
Steps 7. A) through Steps 7. D) are used for Model Years 2005 to 2009 Convertible Mustangs.
Steps 7. E) through Steps 7. G) are used for Model Years 2005 to 2010 Convertible Mustangs.
Steps 7. H) through Steps 7. L) are used for Model Year 2010 Convertible Mustangs.
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(05-09 Mustang)
A) Locate the Decklid wiring connector
under the trunk ledge on the
passenger side of the trunk. Unplug
this connector. Refer to Figure 19.
(05-09 Mustang)
B) Locate the Tan w/ Light Blue Tracer
wire in cavity #2 (cavity #s can be
found on the back edge of the
connector body) of the car side of the
connector. Refer to Figure 20. Depin this wire as per the General Wire
De-pinning Procedure previous to
this section. Pull this wire back an
inch or two loose from the rest of the
harness removing any harness tape
necessary.
Figure 19
(05-09 Mustang)
C) Locate the pin on the supplied
harness that is furthest from the small
black connector that is also on the
supplied harness (L11 is printed on
the wire). Insert this pin into cavity
#2 in place of the pin you just
removed. Refer to Figure 21. Cut off
the pin from the Tan w/Lt. Blue wire
and strip off 3/8” of insulation. Insert
stripped portion into the pink crimp
connector and crimp the center, metal
portion of the connector. Using a
Heat Gun or similar tool, Heat the
pink crimp connector to shrink and
seal the connector.
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Figure 20
Figure 21
1-800-59-ROUSH
Follow this harness
from the trunk
(05-09 Mustang)
D) Tape the new harness to the existing
harness and route the new harness
behind the carpeted trim panels and
forward, following the factory harness,
to the rear seat. Refer to Figure 22.
Figure 22
(05-10 Mustang)
E) Locate the Convertible Top Position
Sensor harness in the passenger side
quarter panel pocket just rear of the
speaker. Refer to Figure 23.
Figure 23
(05-10 Mustang)
F) Unplug this connector and locate the
White w/Violet tracer wire (05-09),
Yellow w/Gray tracer wire (2010) in
cavity #2. De-pin this wire as per the
General Wire De-pinning Procedure
previous to this section. Refer to
Figure 24. Pull this wire back an inch
or two loose from the rest of the
harness removing any harness tape as
necessary.
Figure 24
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(05-10 Mustang)
G) Insert the remaining new harness pin
(L12B is printed on the wire) into
cavity #2. Cut off the pin terminal
from the White w/Violet tracer wire
(05-09), Yellow w/Gray tracer wire
(2010) and strip off 3/8” of the
insulation. Insert the stripped portion
into the pink crimp connector and
crimp the center, metal portion of the
connector. Using a Heat Gun or
similar tool, Heat the pink crimp
connector to shrink and seal the
connector. Plug in and reattach the
connector. Refer to Figure 25.
Figure 25
Note: Take special care to insure you are inserting the pin into the same
cavity you removed the pin from. There is another empty cavity in
the connector.
(2010 Mustang)
H) Obtain the Light Bar Harness, #R08060005-13-AA, from the Light Bar Kit. Cut the
harness per Diagram 1. Strip the insulation 1/2” from the cut end.
Diagram 1 (2010 Mustang)
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(2010 Mustangs)
I) Locate the wire harness at the right rear corner of the cabin as shown in Figure 26.
Figure 26
(2010 Mustangs)
J) Remove 5-6 inches of the black loom tape (non-sticky) from the body harness as
shown in Figure 27. Locate the Yellow/Gray wire (the only Yellow wire in the
bunch).
Figure 27
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(2010 Mustangs)
K) Using wire strippers remove 3/4” of the wire insulation and splice & solder the
cut / stripped end of the Light Bar Wire Harness to the Yellow/Gray wire. Cover
the splice with electrical tape.
(2010 Mustangs)
L) Rewrap the wire harness with electrical tape.
8. Installation of ROUSH Light Bar:
A) Feed the LED wire down through the loosely installed passenger side Trim Panel Cap
and then through the Light Bar Bracket receiver tube. Evenly lower ROUSH Light Bar
partially into holes. Route the LED wire through the speaker bracket and connect it to
the small black connector on the newly install light harness. Secure wiring with Zip ties.
B) Install the upper, passenger side portion of the Quarter Trim Panel.
C) Install the passenger side Trim Panel Cap.
D) Evenly lower the ROUSH Light Bar down to the tops of Trim Panel Caps. With the
bottom of the Light Bar flat on the surface of the Trim Panel Caps, tighten the Light
Bar Bracket Set Screw. (Refer to Figure 26)
Figure 26
9. Reinstall your back seat:
A) Reinstall by reversing Step 1.
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10. Wiring Diagram
2010 Cut Here
05-09
05-09
Yellow / Gray 2010
05-09
Diagram 2 (05-10 Mustang)
Congratulations!!! You have completed the installation of the ROUSH Performance
Products, Light Bar Kit. It is recommended that you save all parts removed from your
vehicle during the installation of this kit.
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WARRANTY
All retail parts carry a 90-day warranty from the date of purchase. This warranty covers
defects in materials or workmanship, and does not include (i) normal wear and tear,
environmental conditions, improper installation; (ii) road hazards, misuse, abuse, neglect,
accidents, collision, fire, theft, freezing, vandalism, riot, explosion, or objects striking the
vehicle; (iii) misusing the vehicle, such as driving over curbs, overloading, racing, or using
the vehicle as a stationary power source; (iv) altering, disassembling or modifying the
parts; (v) defects caused or induced by failures, breakdowns, or damage by other parts,
components or the vehicle; (vi) subjecting the parts to excessive moisture or water or any
motor vehicle fluids (e.g.: oil, anti-freeze, battery acid, brake fluid, etc.); (vii) acts of God,
natural disasters and other similar causes beyond the reasonable control of ROUSH; or
(viii) application of chemicals that affect the parts. This Limited Warranty does not cover
surface deterioration of paint, trim, and appearance items that result from use and/or
exposure to the elements, such as stone chips, scratches, bird droppings, lightning, hail,
windstorm, dings, dents, earthquake, road salt, tree sap, water or flood.
ROUSH SHALL NOT BE LIABLE TO REIMBURSE CUSTOMER/DEALER FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES RESULTING FROM THE INSTALLATION OR USE OF ANY
PRODUCT SOLD THROUGH THIS CATALOG OR ARISING OUT OF ANY BREACH OF
WARRANTY. EXCEPT AS MAY BE STATED IN THIS CATALOG, ROUSH DISCLAIMS ALL
EXPRESS AND IMPLIED WARRANTIES, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL
ROUSH’S LIABILITY EXCEED THE PRICE PAID BY CUSTOMER/DEALER FOR PRODUCTS
SOLD REGARDLESS IF ROUSH HAS BEEN ADVISED IN ADVANCE OF ANY POTENTIAL
PROBLEM OR IF A CLAIM IS BASED ON CONTRACT, TORT, STRICT LIABILITY, PRODUCT
LIABILITY OR OTHERWISE. SOME STATES DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF IMPLIED WARRANTIES OR THEIR DURATION, OR LIABILITY FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSIONS OR
LIMITATIONS MAY NOT APPLY.
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