Third Brakelight Relocation to Hardtop
Thread Starter
JK Freak
Joined: Jun 2008
Posts: 663
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From: Plano, Tx
Third Brakelight Relocation to Hardtop
Only have the finished pic, did not think about doing a write up until it was finished and people started asking me how to do it.
You start off with ordering the correct light...
h t t p://stores.ebay.com/Global-Parts-Incorporated
Make sure that you order the 4-wire one.
This will give you Stop/Tail/Turn signals where you only had Stop before.
Pick up some 4-wire trailer wire, some black RTV, h-taps and some connectors from your auto supply store
Then pick up some nylon inserts for mounting and 1 1/2" screws from Lowes or Home Depot
The last thing you will need is an 11x17 piece of craft foam (black) to use for a gasket. (WalMart, Michaels, Hobby Lobby)
You will need to tap into your taillights on the left side.
Trailer Wire ------- Taillights
White -------------- Black
Brown ------------- White w/Orange Stripe
Yellow ------------- White w/Yellow Stripe
Green -------------- White w/Green Stripe
Tap into the tail lights and then route the trailer wire up into the back of the Jeep through the rubber plug that already has wires running through it.
Wrap about 18" with black tape so that it will blend in.
You will need to unplug the electrical and washer connection and then remove the black insert that they connect to on the left rear of your hardtop.
Fish a string with some weight on it down to the hole and reach in and grab the weight.
Run the string through the plastic piece you removed and tie on to the trailer wire
feed the wire up to the cutout at the top of the window and pull your slack through
Close up everything that you have taken apart so far.
If you remove your hard top, you will have to put a connector in-line where the wire goes into the top
Put masking tape across the top, above the window and locate the center
Before you drill any holes, you need to be sure which side is left and what side is right.
This is especially important because the wires do not come out of the center of the light, they are offset by about a half of an inch.
On mine the longest side was the left and the short side was the right.
It is best to temporally wire it up and test the light and mark what side is left with a piece of tape.
Measure and mark the place to drill for the wires considering where the offset hole should be.
Also determine where you want to place the fixture vertically.
On the light fixture...
You will notice that the mounting ends are raised on the back.
In order to mount the fixture flush you will need to sand the raised section flush.
once that is done, make a small hole big enough to put the wires through in the foam sheet towards one long side.
Cut that section out but leave some overhang for trimming later.
Using the RTV, spread it out over the back of the fixture making sure that you have some around the mounting holes and the wires.
Stick the foam to the back of the fixture.
While the RTV sets...
Using a step bit, drill out the entry point for the wires, You need to make it big enough so that the fixture sits flush.
Once you have the center drilled out, insert the wires into the hole and level the fixture.
Using a pilot bit, drill pilot hole in both ends.
Using your step bit again slowly enlarge the mounting holes until the nylon inserts fit snugly.
Remove the masking tape and clean the area with alcohol
After the RTV sets...
Fish the trailer wire across to your new hole and cut it down as needed.
Use your connectors to attach the wires to the fixture wires.
Use the RTV again on the back side of the foam gasket making sure the there is plenty around the wires and the mounting holes.
Insert the connected wires into the hole and seat the fixture flush, insert and hand tighten the the 2 mounting screws.
Take a razor blade or sharp knife and trim the gasket flush.
Clean up excess RTV with alcohol.
For the existing light, I removed it and cut the top off just below the top edge of the tire and cut and taped up the old wires and stuck them back inside the tailgate.
Stand back and admire your work ( after a final test )
This should only take a couple of hours to complete.
Thanks to Christine for the idea and the link!
You start off with ordering the correct light...
h t t p://stores.ebay.com/Global-Parts-Incorporated
Make sure that you order the 4-wire one.
This will give you Stop/Tail/Turn signals where you only had Stop before.
Pick up some 4-wire trailer wire, some black RTV, h-taps and some connectors from your auto supply store
Then pick up some nylon inserts for mounting and 1 1/2" screws from Lowes or Home Depot
The last thing you will need is an 11x17 piece of craft foam (black) to use for a gasket. (WalMart, Michaels, Hobby Lobby)
You will need to tap into your taillights on the left side.
Trailer Wire ------- Taillights
White -------------- Black
Brown ------------- White w/Orange Stripe
Yellow ------------- White w/Yellow Stripe
Green -------------- White w/Green Stripe
Tap into the tail lights and then route the trailer wire up into the back of the Jeep through the rubber plug that already has wires running through it.
Wrap about 18" with black tape so that it will blend in.
You will need to unplug the electrical and washer connection and then remove the black insert that they connect to on the left rear of your hardtop.
Fish a string with some weight on it down to the hole and reach in and grab the weight.
Run the string through the plastic piece you removed and tie on to the trailer wire
feed the wire up to the cutout at the top of the window and pull your slack through
Close up everything that you have taken apart so far.
If you remove your hard top, you will have to put a connector in-line where the wire goes into the top
Put masking tape across the top, above the window and locate the center
Before you drill any holes, you need to be sure which side is left and what side is right.
This is especially important because the wires do not come out of the center of the light, they are offset by about a half of an inch.
On mine the longest side was the left and the short side was the right.
It is best to temporally wire it up and test the light and mark what side is left with a piece of tape.
Measure and mark the place to drill for the wires considering where the offset hole should be.
Also determine where you want to place the fixture vertically.
On the light fixture...
You will notice that the mounting ends are raised on the back.
In order to mount the fixture flush you will need to sand the raised section flush.
once that is done, make a small hole big enough to put the wires through in the foam sheet towards one long side.
Cut that section out but leave some overhang for trimming later.
Using the RTV, spread it out over the back of the fixture making sure that you have some around the mounting holes and the wires.
Stick the foam to the back of the fixture.
While the RTV sets...
Using a step bit, drill out the entry point for the wires, You need to make it big enough so that the fixture sits flush.
Once you have the center drilled out, insert the wires into the hole and level the fixture.
Using a pilot bit, drill pilot hole in both ends.
Using your step bit again slowly enlarge the mounting holes until the nylon inserts fit snugly.
Remove the masking tape and clean the area with alcohol
After the RTV sets...
Fish the trailer wire across to your new hole and cut it down as needed.
Use your connectors to attach the wires to the fixture wires.
Use the RTV again on the back side of the foam gasket making sure the there is plenty around the wires and the mounting holes.
Insert the connected wires into the hole and seat the fixture flush, insert and hand tighten the the 2 mounting screws.
Take a razor blade or sharp knife and trim the gasket flush.
Clean up excess RTV with alcohol.
For the existing light, I removed it and cut the top off just below the top edge of the tire and cut and taped up the old wires and stuck them back inside the tailgate.
Stand back and admire your work ( after a final test )
This should only take a couple of hours to complete.
Thanks to Christine for the idea and the link!
Last edited by cppower; Oct 17, 2010 at 01:02 PM. Reason: Adding Credits
Got any pics from the inside? 
