Index

INTRODUCTION: BEFORE ATTEMPTING ANY REPARS, REVIEW THIS BOOK TO FAMILIARIZE YOURSELF WITH THE PROCEDURES, COMPONENTS AND TERMINOLOGY.
LEAK AREA
REFER PAGE 2. PAGE TITLE

OPERATION AND MAINTENANCECHRYSLER "T" ROOF:

OPERATION AND MAINTENANCE FOR CHRYSLER T-ROOF (VEHICLE INSERT)

T-ROOF EXPLODED VIEW:

1. T-ROOF EXPLODED VIEW-PART IDENTIFICATION

POSSIBLE LEAK AREAS:

2. POSSIBLE LEAK AREAS

DIAGNOSTIC CHART:

* 3. DIAGNOSTIC CHART
* 4. DIAGNOSTIC CHART CONT. REPAIRS

ROOF WEATHERSTRIPREMOVAL:

1-2-3-4-5
7-11-12-13 5. ROOF WEATHERSTRIP - REMOVAL

ROOF WEATHERSTRIPINSTALLATION:

1-2-3-4-5 6. ROOF WEATHERSTRIP - INSTALLATION
7-11-12-13

ROOF SEAL DRAIN AREAFINAL PREP:

3-7-8-13 7. ROOF SEAL DRAIN AREA - FINAL PREP

SIDE RAIL SEALREMOVAL:

1-2-6 8. SIDE RAIL SEAL - REMOVAL

SIDE RAIL SEALINSTALLATION:

1-2-6 9. SIDE RAIL SEAL - INSTALLATION

GLASS PANEL ALIGNMENT:

1-2-7 10. GLASS PANEL - ALIGNMENT

DOOR GLASS ADJUSTMENT:

1-2-4-5 11. DOOR GLASS - ADJUST

DOOR GLASS REMOVAL & INSTALLATION:

12. DOOR GLASS - REMOVAL & INSTALLATION

DOOR FRAME SEALSREMOVAL & INSTALLATION:

4-5 13. DOOR FRAME SEAL
(CAPS) REMOVAL & INSTALLATION
LEAK AREA
REFER PAGE 2. PAGE TITLE

DOOR MOLDINGREMOVAL & INSTALLATION:

14. DOOR BELT MOLDNG - REMOVAL & INSTALLATION

UPPER A & B PILLAR TRIM CAP'SREMOVAL & INSTALLATION:

1-2 15. " A" & "B" PILLAR TRIM CAPS - REMOVAL &
INSTALLATION

OUTER ROOF MOLDING& P-SEAL REMOVAL:

3-8-13 16. OUTER ROOF MLDG. & "P" SEAL
REMOVAL & INSTALLATION

OUTER ROOF MOLDING& P-SEALINSTALLATION:

17. OUTER ROOF MLDG. & "P" SEAL -
3-8-13 REMOVAL & INSTALLATION

"A" PILLAR MOLDINGREMOVAL & INSTALLATION:

12 18. "A" - PILLAR MLDG. - REMOVAL & INSTALLATION

"B" PILLAR MOLDINGREMOVAL & INSTALLATION:

11 19. "B" - PILLAR MLDG. - REMOVAL & INSTALLATION

HEADLINER REMOVAL:

20. HEADLINER - REMOVAL

HEADLINERINSTALLATION:

21. HEADLINER - INSTALLATION

CENTER BAR GLASS RESTRAINTREMOVAL & INSTALLATION:

7 22. CENTER BAR GLASS RESTRAINT - REMOVAL -
INSTALLATION

23. WINDSHIELD REMOVAL AND INSTALLATION
* REFER TO DIAGNOSTIC CHART AS AN AID TO DETERMINE WATERLEAK ENTRY AND REPAIR.

REMOVAL & INSTALLATION WINDSHIELD

REMOVAL REMOVE ROOF MOLDINGS AS OUTLINED ON PAGES 16 & 18. PLACE PROTECTIVE COVERINGS OVER THE AREAS ADJACENT TO THE GLASS BEING REPLACED. REMOVE BOLTS FROM HOOD HINGES THAT ALLOW HOOD TO MOVE FORWARD, AS SHOWN IN (FIG.1), THEN PULL HOOD TO FORWARD POSITION. REMOVE "A" PILLAR MOLDING AND HEADER ROOF MOLDINGS, AS SHOWN ON PAGES 16 & 18. CAREFULLY REMOVE GLASS RETAINER BY PULLING IT FROM THE URETHANE. REMOVE INTERIOR GARNISH MOLDING, IF NECESSARY, AND CUT GLASS FROM OPENING USING AN ELECTRIC KNIFE, AS CLOSE TO THE GLASS AS POSSIBLE. SHAVE DOWN ANY HIGH SPOTS OF URETHANE FROM THE FENCE FLANGE USING A UTILITY KNIFE TO ALLOW A FLUSH GLASS INSTALLATION (COMPLETE URETHANE REMOVAL IS NOT NECESSARY). USING URETHANE METAL PRIMER, PRIME ANY BARE METAL SPOTS ON FENCE FLANGE, ALLOW 18 MIN. DRY TIME. NOTE: IF URETHANE COVERS THE COMPLETE PERIPHERY OF THE FENCE FLANGE, THE USE OF METAL PRIMER WILL NOT BE NEEDED. CLEAN THE INSIDE OF OUTER EDGE OF GLASS USING NAPHTHA OR OTHER EQUIVALENT SOLVENT TO REMOVE RESIDUE. IN A VERY WELL VENTED AREA, PRIMER THE INSIDE OUTER PERIPHERY OF THE GLASS 15.88 MM (5/8"), FROM THE EDGE, USING A WIPE OFF URETHANE GLASS PRIMER. WIPE EDGES DRY AFTER PRIMER APPLICATION. APPLY SPACER DAM TO THE INSIDE OUTER PERIPHERY OF THE GLASS, 9.5 MM (3/8") FROM EDGES USING A HOT MELT GLUE GUN, AS SHOWN IN (FIG.2), IF THE FENCE FLANGE IS CLEAN AND NO URETHANE EXISTS.

INSTALLATION

IF WINDSHIELD IS TO BE REPLACED INSTALL TEN SPACERS TO THE BODY, AT THIS TIME. PLACE GLASS INTO OPENING WITH SPACERS IN PLACE. ALIGN GLASS TO OPENING WITH 2.8 MM (7/64) OPENING BETWEEN EDGES OF GLASS AND UPPER ROOF FLANGE, AS SHOWN IN (FIG. 3). (SHIM SPACERS, AS REQUIRED, TO ACHIEVE OPENING). MAKE ALIGNMENT MARKS ON GLASS TO BODY IN FOUR PLACES USING MASKING TAPE OR GREASE PENCIL, FOR REVERENCE. REMOVE GLASS FROM OPENING AND PLACE ON FIAT SURFACE. TH0ROUGHLY MIX AND APPLY URETHANE GIASS PRIMER (BLACKOUT) TO THE INSIDE OUTER PERIPHERY OF GLASS BETWEEN SPACER DAM AND EDGE. ALLOW 3 MINUTES DRY TIME. AVOID EXCESS USE OF PRIMER. APPLY A BEAD OF URETHANE 9.5 MM (3/8") WIDE BY 13 MM (1/2") HIGH BETWEEN SPACER DAM AND EDGE, AS SHOWN IN (FIG. 4). ONLY USE A 6.4 MM (1/4") BEAD OF URETHANE WHEN SPACER DAM IS NOT USED. INSTALL GLASS TO OPENING, USING THE REFERENCE MARKS FOR ALIGNMENT.
NOTE: GLASS MUST BE INSTALLED WITHIN 20 MINUTES OF BEAD APPLICATION. REMOVE EXCESS URETHANE SEALER USING NAPTHA OR EQUIVALENT SOLVENT. SEAL HOLES IN "T" -ROOF FRAME WHERE MOLDING WAS ATTACHED, WITH A BUTYL SEALANT. THEN, REPLACE HEADER ROOF MOLDING AND "A" PILLAR MLDGS. (REFER TO PAGES 17 & 18) WATER TEST ASSEMBLY. IF ADDITIONAL SEALING IS REQUIRED, A PUMPABLE BUTYL SEALER MAY BE USED.