ZROADZ Z845401 User manual

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START HERE
PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE INSTALLATION.
Auto makers offer varied models to each vehicle and occasionally manufacture
more than one body style of the same model. To assure your part is correct; our tech
department can be contacted at [email protected] to verify fitment and assist with
technical questions. All other inquires can be directed to [email protected]. In the
event you do not have internet access please call 844-653-8040
* APPLICATION MODELS VARY. WE RECOMMEND TO VERIFY FITMENT BEFORE BEGINING INSTALLATION PROCESS.
* IMAGES FEATURED IN THE INSTRUCTION DOCUMENTS MAY NOT ALWAYS EXACTLY MATCH YOUR MODEL OR PART.
Parts included
hardware INCLUDED
Installation Guide
STEP 2
Z845401
(6) M6 x 1.0 MM x 16 MM Screw (Black Oxide)
(10) M8 x 1.25 MM x 30 MM Screw (Black Oxide)
(24) M8 x 1.25 MM x 20 MM Screw (Black Oxide)
(8) M8 x 1.25 MM Flange Nut
(34) Split Lock Washer for M8 Screw Size (Black Oxide)
(8) M6 Washer
(4) M6 x 1.0 MM x 20 MM Screw (Black Oxide)
(4) M6 Lock Nut
(8) M8 Hex Nut (Stainless Steel)
(8) M8 x 20 MM Hex Head Cap Screw
(8) 3/8 "x 7.8" Metal Washer
(8) M8 Split Lock Washer
(4) 1/32" Rubber Padding
(8) 1/8" Rubber Padding
(4) 1/8" x 2" x 39" Rubber Padding
(10) Zip Ties
Z325411
Same as Z845401 but includes
(8) 3" LED Pod Lights (6 White, 2 Amber) + Wiring
Z845421
Same as Z845401 but includes
(8) 3" LED Pod Lights (6 White, 2 Amber) + Wiring
(1) 30" Light Bar + Wiring + Brackets
(2) 1/4" - 20 Nylon Lock Nut
(2) 1/4" x 5/8" Flat Washer
ALL Z8454XX MODELS
(1) Front Crossbar w/ LED Bracket
(1) Side Tubing Assembly (Left)
(1) Side Tubing Assembly (Right)
(1) Front Left Mounting Assembly
(1) Front Right Mounting Assembly
(1) Rear Tubing Assembly
(2) Mid Clamping Bracket
(1) Rear Clamping Bracket (Left)
(1) Rear Clamping Bracket (Right)
(2) Mid Crossbar
(2) Rear Crossbar
2) As shown to the left, install the provided (8) pieces of
1/8" Rubber Padding onto the bottom of each base.
STEP 1
NOTE BEFORE YOU START INSTALLATION
Not included but required
•Blue Threadlocker
•Hand tools set
•(2) 60 in. x 2 in. x 4 in. Spacers or similar to
install accessories on rack prior to attachment
to the vehicle.
1) Remove the windshield caps to expose the roof rack
mounting points by depressing the tab on the back side
of the cover located closest to the roof panels.
2021 FORD BRONCO
(Fits all except soft top)
4 DOOR -Z845401, Z84541 1, Z845421
CARGO RACK
© COPYRIGHT 2021 - ALL RIGHTS RESERVED- ZROADZ LED, INC.

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nstallation - Continued
STEP 3
3)As shown above, install the (4) pieces of 1/32" Rubber Padding between
the bend of the (4) Clamping Brackets.
STEP 5
4)Assemble the male rear round center cross bar and side tube
assemblies. Using (8) split lock washers and (8) M8 x 1.25 MM x 20 MM
screws attach the rear crossbars to each pair of rear bases. (2x)
6)As shown above, place the mid crossbars onto the bar brackets.
Align them to the slots for your desired configuration.
5)Rear crossbars should be installed as shown above along
with the male rear round center cross bar.
STEP 4
STEP 6
© COPYRIGHT 2021 - ALL RIGHTS RESERVED- ZROADZ LED, INC.

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nstallation - Continued
STEP 7
7)Install each mid crossbar using (4) split lock washers and (4) M8 x 1.25
MM x 20 MM screws (2x). Do not tighten completely at this time.
STEP 9
8)Insert the front mounting assembly into the side tube assembly. Notice
that each assembly corresponds to a particular side that is distinguished
through the holes found only on one of its sides. Once identified, match
these holes with the front crossbar flange and install the crossbar using (1)
M6 x 1.0 MM x 20 MM screw, (1) M6 lock nut and (2) M6 washers for each
flange hole (4x). Do not tighten completely at this time.
10)Apply (2) pieces of 39" rubber padding onto each mid crossbar.
9)Secure each front mounting assembly to its side tube assembly
using (1) split lock washer and (1) M8 x 1.25 MM x 30 MM screw as
shown above. Do not tighten completely at this time.
STEP 8
STEP 10
© COPYRIGHT 2021 - ALL RIGHTS RESERVED- ZROADZ LED, INC.

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nstallation - Continued
STEP 11
11)Apply (2) pieces of 39" rubber padding onto each rear crossbar.
STEP 13
12)If purchased, install the (8) ZROADZ LED pod lights and the 30" light
bar. Tighten the mid crossbar bolts from STEP 7.
14)Position the rack so that its front mounting bracket assemblies are
directly above the factory roof rack mounting points. The front cross
bar fasteners from STEP 8 and STEP 9 should be loose.
13)With some help, lift the rack onto the roof of the truck. Any
accessories should be attached to the rack at this step. Use (2) 2 x
4 wood boards or similar to position the rack on the roof and install
accessories.
STEP 12
STEP 14
© COPYRIGHT 2021 - ALL RIGHTS RESERVED- ZROADZ LED, INC.

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nstallation - Continued
STEP 15
15)Ensure that the mid and rear bases are aligned to sit on the lower part
of the roof.
STEP 17
16)Once the rack has been aligned and accessories installed, lower the
front brackets over the front factory mounting studs. The holes found on
the bottom of the ZROADZ front brackets install over the factory
accessory mounting studs as shown above. Use the factory nuts to
secure the brackets.
18)With the rack aligned, tighten the front crossbar and tube bolt from
STEP 8 and STEP 9.
17)Install the (4) clamping brackets using (2) split lock washers and (2)
M8 x 1.25 MM x 30 MM screws for each clamp base and bracket. Notice
that there are (3) different clamping brackets. The brackets that are similar
will need to be installed on the brackets closest to the front of the vehicle.
The other two which are right and left sides will be installed in the rear.
(Use blue threadlocker) on all clamp fasteners.
STEP 16
STEP 18
© COPYRIGHT 2021 - ALL RIGHTS RESERVED- ZROADZ LED, INC.

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nstallation - Continued
STEP 19
19)Using (3) M6 x 1.0 MM x 16 MM screws for each side, secure the
cover onto each front mounting assembly (Use bluethreadlocker). Its
corresponding side will be marked by a sticker identifying its correct
side. Do not overtighten.
© COPYRIGHT 2021 - ALL RIGHTS RESERVED- ZROADZ LED, INC.

ZROADZ PRODUCT WARRANTY
ZROADZ warrants its grille products to be free from defects in material and workmanship for the lifetime of the grille. ZROADZ warrants the
finish of its grille products for a 3 year period beginning at the time of sale to the end user. These warranties are limited warranties and do
not cover abuse, modification or improper installation nor do they cover finish failure caused by caustic cleaning agents, road salts or other
chemicals. ZROADZ reserves the right to repair or replace a defective product at its sole discretion. Any ZROADZ product must be returned to
ZROADZ for warranty consideration and must be returned at the customer’s expense. In the event that the product is deemed to be defective,
the repaired or replaced item will be returned via a surface shipping method to the customer at ZROADZ expense. No provision is made for
any labor, rental car or other costs incurred by the failure of its products.
GENERAL GUIDELINES
LED Lights & LED Light Bars operate at relatively high currents and should only be installed by qualified personnel with experience in
switched / relayed high draw DC Circuits.
- Light Bars are designed for use only with standard 12v DC power systems
- Light Bars are for OFF-ROAD USE ONLY. Check your local laws & regulations regarding vehicle mounted lights.
- Some Light Bars are equipped with waterproof connectors while others are simply pig-tailed
- Red Wires = POSITIVE | Black Wires = NEGATIVE
- ALWAYS install your lights on a fused circuit. Basic fusing guidelines: maximum 5A for every 10” of LED Light Bar.
WARNING
PLEASE CONSULT YOUR LOCAL AUTOMOTIVE ELECTRICAL PROFESSIONAL FOR INSTALLATION SERVICES AND ADVICE. ZROADZ IS ONLY
EQUIPPED TO PROVIDE BASIC TECHNICAL ASSISTANCE DUE TO THE DIVERSITY OF VEHICLES, VEHICLE OPTIONS & MODIFICATIONS AND
LIGHTING CONFIGURATION OPTIONS AVAILABLE. ZROADZ cannot be held liable due to improper component installation and / or faulty wiring.
GENERAL USE, INSTALL AND ADJUSTMENT TIPS
NOTE 1: ZROADZ LED Light Bars themselves are for OFF-ROAD USE ONLY.
NOTE 2: Light Bars depending on the configuration of your vehicle and its options and/or modifications may need to be adjusted for appropriate
beam projection. To adjust the angle of your light bars simply loosen the mounting hardware on either side of each Light Bar, rotate the Light Bar
to adjust the angle, then tighten the hardware once the desired angle is achieved (please be careful not to over-tighten the mounting hardware or
scratch the protective powder-coat finish). It is best to adjust the angle with the vehicle on level ground with the lights facing a wall, garage door
or other solid barrier at a distance of approximately 25-30 feet.
NOTE 3: Please consult a qualified automotive electrical professional for light bar wiring installation.
NOTE 4: An optional universal wiring harness (part# Z390020S-A) is also available that includes high-heat & oil/fuel resistant wires, waterproof
connector, 12v relay, 12v rocker switch, inline fuse holder. Our universal wiring harness significantly expedites the installation process but is not a
vehicles specific “Plug & Play“ product and does not eliminate the need for a professional installation.
Please contact your local ZROADZ dealer for more information or visit www.zroadz.com.
PRODUCT CARE INFORMATION
Wash regularly as you would when caring for your vehicles. Never use dish soap. Never leave wet water spots as that may leave a blemish.
GLOSS BLACK FINISH
ZROADZwith Gloss Black Powder Coated Finish may be washed regularly as you would when caring for your vehicles finish using soap and
water. ZROADZshould be waxed at the same time that you wax the vehicle. As a general rule, anything you use to clean your vehicles painted
surfaces can be used to clean and maintain your ZROADZ grille. A Gloss powder Coated Finish can be cared for in the same fashion that you
would care for your vehicles factory paint job. Never leave wet water spots as that may leave a blemish.
MATTE BLACK FINISH
Paint warranty applies to defects in material and / or workmanship, it does not cover the matte finish surface appearance.
To enjoy the matte appearance for many years to come, please follow these owner care and maintenance tips.
Get a no-shine matte car wash soap that uses no fillers, no silicone, and won’t strip your matte paint of its layer of protection.
Do not use wax, detail spray, armorall®, or any products made for normal paint. Use only products specifically developed for matte
finish paint. Do not use products that are even mildly abrasive, such as polishes, glazes, or rubbing compounds. Do not use mechanical
cleaners or polishers. Do not use terrycloth, cloth, or paper towels. Do not rub the finish vigorously, this will burnish the paint finish,
causing a permanent shiny spot. Shiny spots cannot be removed.

Do not use commercial car wash facilities or their shine enhancement products. Most car wash brushes, large mechanized “towels,”
and shine enhancement products can damage matte paint.

Remove foreign substances such as insect remains, tar, and road debris using a soft applicator and a mild solvent; saturate and soak
area before cleaning—rub lightly.

Hand-wash with a soft wash mitt and mild cleaning product safe for matte paint. Use microfiber cleaning cloths with alcohol-based window
cleaner for basic surface clean-up.
zroadz PRODUCT WARRANTY
LED Lighting Equipment Installation / Disclaimer
PRODUCT Care Information
Parts are PATENT PENDING. All Rights
Reserved - Copyright ©2015 - ZROADZ.com
© COPYRIGHT 2021 - ALL RIGHTS RESERVED- ZROADZ LED, INC.

MOUNTING YOUR LIGHTS
1. Choose a location on your vehicle to mount your light(s). Install the light(s) and loosely tighten.
You will secure them later when aiming.
WIRING YOUR LIGHTS
1. Remove the fuse from the harness. Find a suitable
location inside the passenger compartment for your
switch. Mark and drill a single hole with 49/64" Drill
Bit. You may use the featured Diagram Template to
mock up, position, and measure. Next carefully file 3
notches as shown.
2. Connect the harness to the light(s) and route the
harness back towards the battery. Attach the RED
wire to the positive side of the battery or power
source. Attach the BLACK wire to the negative side
of the battery or chassis ground.
3. Continue routing the switch side of the harness into
the vehicle. Once the wires are inside the vehicle
install the switch to the hole drilled during Step 1.
4. Before replacing the fuse, ensure the switch is in
the off position (see below). Replace the fuse and
turn on your lights.
AIMING YOUR LIGHTS
Fog Lights - The vertical aiming of fog lights is very important. Because of the low mounting position relative to the ground (12
to 30 inches), they should be aimed parallel to the ground or lower. Fog lights should be aimed so the cutoff is on or below
your horizontal low beam for best results. The side to side adjustments are up to you. A large center overlap will increase
center light and decrease overall width. A slight center overlap will increase your side lighting and give even coverage overall.
Driving Lights - Driving lights are used to supplement your high beams. They should only be used in conjunction with high beam
headlights. The horizontal centers of the beams may be aimed at the same level as your high beam.
The width is up to you as you may prefer to light the sides of the road at a distance rather than
concentrating the majority of the light down the middle.
Off Road Lights - Since lights such as these are not legal on any public road or highway, aiming
your off road or competition lights is entirely up to you. Most prefer the beam as far down the
road as possible, others adjust them slightly off to the sides.
After aiming the lights to your preference, tighten all hardware.
© COPYRIGHT 2021 - ALL RIGHTS RESERVED- ZROADZ LED, INC.

USE OF THIS PRODUCT
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WARANTY
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