Folding Top Hydraulic Cylinder Replacement

FOLDING TOP HYDRAULIC CYLINDER REPLACEMENT

REMOVAL PROCEDURE
1. Cycle the folding top stowage lid open.

CAUTION: Refer to Eye Protection Caution in Service Precautions.

CAUTION: Refer to Folding Top Hydraulic Pressure Caution in Service Precautions.

CAUTION: Refer to Servicing Electrical Components Caution in Service Precautions.

2. Stop the cycle before the folding top panel is unlatched from the windshield header.
3. Place a protective cover on all adjacent body panels and quarter panels.
4. Remove the stowage compartment lid assembly.
5. Cycle the folding top until the front panel is unlatched from the windshield header.
6. Remove the rear upper garnish molding.
7. Remove the front headliner.
8. Remove the side headliner.
9. Remove the folding top front panel.
10. Remove the folding top rear panel.




11. Using a grease pencil or suitable marking device, mark alignment marks onto the bulkhead for realignment.
12. Remove the necessary zip-ties to aid in removal of the folding top side rail assembly.
13. Remove the lock pillar trim.




14. Remove the folding top side rail fasteners.




15. Carefully lift the folding top side rail assembly upward to access the main lifting cylinder.
16. Remove the lower retaining clip from the clevis pin. Note the spacer placement prior to removal.
17. Remove the lower clevis pin and spacers.
18. Remove the upper retaining clip from the clevis pin.
19. While supporting the cylinder, remove the upper clevis pin.
20. Remove the necessary zip-ties in order to remove the hoses from the main lift cylinder.




21. Remove the side rail assembly from the vehicle.
22. Slide the gray cylinder cover back about 3 mm (0.118 in). Squeeze the black tab and disconnect the main cylinder position sensors electrical connectors. Cut the tie straps and electrical tape as needed. Mark the location of the cylinder sensors prior to removal.
23. Place the main lift cylinder in a catch pan.

DISASSEMBLY PROCEDURE
1. Ensure that the ignition switch is in the OFF position and that the folding top has not been operated under power for at least 6 minutes.

NOTE: Refer to Cylinder Hoses Notice in Service Precautions.

IMPORTANT: Once the cylinder hose of the port plug has been removed, DO NOT move the cylinder rod. Moving the cylinder rod will cause fluid to squirt out of the port.




2. Using a flat-bladed tool, release the retainer clips (1) from one of the cylinder hoses.

IMPORTANT: Before disconnecting the cylinder hoses, have the replacement cylinder ready.

3. Remove the cylinder hose retainer clips.




4. Remove the cylinder hose (1). Use a clean shop towel to control any hydraulic fluid leakage.




5. Using a plastic or wood tool, remove the cylinder hose O-ring (1).
6. Using a small flat-bladed tool, release one of the port plug retainer clips from the replacement cylinder.
7. Remove the retainer clips from the replacement cylinder.
8. Remove the port plug from the replacement cylinder.

IMPORTANT: Replacement cylinders are prefilled with fluid. DO NOT remove the port plug from the cylinder until you are ready to connect the cylinder hose.

9. Remove the port plug O-ring (1) from the replacement cylinder.

ASSEMBLY PROCEDURE




1. Lubricate and install a new O-ring (1) onto the cylinder hose (2).
2. Install the hose into the cylinder port (3). Press down on the hose until the hose is fully seated in the cylinder. Keep the hose as parallel with the cylinder as possible.




3. Install the cylinder hose retainer clip (1). Inspect the retainer clip to ensure that the clip is fully seated around the hoses (2).
4. Repeat this procedure for the other hose.

INSTALLATION PROCEDURE
1. Connect the main cylinder position sensors electrical connectors.




2. Install the side rail assembly to the vehicle.
3. While supporting the cylinder, install the upper clevis pin.
4. Install the upper retaining clip for the clevis pin.
5. Install the lower clevis pin and spacers.
6. Install the lower retaining clip for the clevis pin.
7. Connect the electrical connectors to the main cylinder position sensors. Fully seat the gray cover. Use new tie straps and re-tape as needed.
8. Install the folding top side rail into the vehicle.




9. Install the folding top side rail fasteners. Hand tighten the fasteners.
10. Align the side rail to the alignment marks on the bulkhead.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the folding top side rail fasteners to 45 N.m (33 lb ft).

11. Install the lock pillar trim.
12. Route the down capture latch cable in the stowage compartment area.
13. Install the removed zip-ties for proper cable/hose routing.
14. Install the folding top rear panel into the vehicle.
15. Install the folding top front panel into the vehicle.
16. Install the side headliner.
17. Install the front headliner.
18. Install the rear upper garnish trim.
19. Cycle the folding top until the front panel is latched into the windshield header.
20. Install the stowage compartment lid assembly.
21. Remove the protective covers from the vehicle.
22. Bleed the hydraulic system. Refer to Folding Top Hydraulic System Bleeding Procedure.
23. Inspect the hydraulic system for any oil leaks.
24. Inspect the fluid level and add fluid as needed.
25. Inspect the folding top for proper operation.