Leading Edge Trailing Edge Replace
Millennium Light Bar: Lens Kit Retro-Fit You will need the following tools before you start: 1 - Flat head screw driver or electric drill driver 1 - Spanner bit # 14 (provided in kit) and a socket tool to accept the bit 1 - Container for the parts being replaced 1 - Step stool or riser (If unable to reach top of vehicle) 1 – 5/32” Allen Wrench First, do not remove all the lenses from the leading or trailing edge at one time. The lens assemblies hold two circuit boards in place inside the light bar and removing all of them could dislodge them, rendering the light bar useless. Instead, begin with replacing all but the first and last segments. This will ensure that the internal circuit boards remain in place.
Leading Edge
Replace these segments last
Trailing Edge Remove each lens with the flat-headed screwdriver and take everything off of the assembly. The only part that you will reuse is the LED Segment. Note: If the outer two lens segments on the leading and trailing edge are too tight to remove by hand, loosen the bolts that secure the mounting on the bottom-side of the light bar with a 5/32” allen wrench. Now, insert the new insulators, setting the LED Diode on them. Make sure that the lens shows the 911EP logo on the bottom left corner. The reflector’s guide pin should match up with a hole in the light bar’s chassis. Ensure that the lens gasket is in proper alignment with the lens. Insert the new shoulder bolts and tighten both together. (See illustration below) Do not tighten one side fully before the other. The use of a power drill is not recommended for the new, composite-headed bolts, however, if necessary, use the lowest torque setting attainable. Note: Be very careful of the new shoulder bolts: the head of the bolt can chip if too much pressure is applied!
If you have any questions or problems, please call the Customer Service Department immediately @1-800-863-6911for assistance.
Leading Edge
Replace these segments last
Trailing Edge Remove each lens with the flat-headed screwdriver and take everything off of the assembly. The only part that you will reuse is the LED Segment. Note: If the outer two lens segments on the leading and trailing edge are too tight to remove by hand, loosen the bolts that secure the mounting on the bottom-side of the light bar with a 5/32” allen wrench. Now, insert the new insulators, setting the LED Diode on them. Make sure that the lens shows the 911EP logo on the bottom left corner. The reflector’s guide pin should match up with a hole in the light bar’s chassis. Ensure that the lens gasket is in proper alignment with the lens. Insert the new shoulder bolts and tighten both together. (See illustration below) Do not tighten one side fully before the other. The use of a power drill is not recommended for the new, composite-headed bolts, however, if necessary, use the lowest torque setting attainable. Note: Be very careful of the new shoulder bolts: the head of the bolt can chip if too much pressure is applied!
If you have any questions or problems, please call the Customer Service Department immediately @1-800-863-6911for assistance.
