Repair Procedure

This bulletin involves the replacement of the right and left side rails within the top assembly.





1. Remove the top and place on a flat surface ( Figure 1).

2. Remove the foam pad from the right and left rear pivot and discard.





3. With the interior side facing up, remove the clip, disengage the left and right side rails and fold back the rear header to expose the side rail rear pivot screws ( Figure 2).





4. Remove nut, screw/washer combination and 2 large nylon washers from each pivot and save for installation (Figure 3).

5. Remove rail from pivot.

6. Place new rail into the pivot, sandwiching the 2 large nylon washers on either side of rear header.

7. Install the nut onto the pivot and hold in place as screw/washer combination is threaded in from opposite side and torque to 5.6 Nm (50 in.lbs), (Figure 3).

8. Repeat steps 6 thru 8 for other side rail.

9. Turn front header upside down to expose the threaded pin used for the original side rail engagement.

10. Remove threaded pin from header from both sides (L/R).

11. Push both new rails onto front header to begin assembling the top.





12. With the outboard of the rail held to the bottom of header firmly, drill 1/4" hole into header (drilling depth is 23 mm (0. 909") use the existing hole in the rail as a guide (Figure 4).

CAUTION:
IT IS IMPORTANT THAT THE HOLE IS DRILLED ONLY THROUGH THE HEADER. DO NOT DRILL FURTHER THAN 23 MM.

13. Repeat step 12 for other side.

14. Disengage rail from front header and turn front header inside out.

15. Push back fabric to allow clear access to new hole (drilled in step 12) in header.





16. Enlarge existing 1/4" hole to 5/16" hole by drilling from backside to the front (Figure 5).

17. Repeat the procedure for the other side.

18. After drilling, clean top of all debris.





19. Install 6 velcro patches to bow feet of 3 bows (Figure 6).





20. Install the foam seal pads to both pivot corners (right side shown in Figure 7).

21. Assemble and install retention screws to the rail.





22. Add a velcro strip to the front of each rail next to the retention screw. The velcro strip can be used with the attaching strap at the front of the side curtain ( Figure 8).

23. Try top assembly on vehicle by engaging the front header first, then check the rear scissor latch location in relation to the front pin. If adjustment is needed, complete step 24 to step 29.

24. With top in upside down position and rear header towards you adjust the rear scissor latch to the proper position.





25. Remove the 2 U-shaped foam seals covering the latch screws and discard (Figure 9).

26. Loosen the latch screws to the appropriate latch or latches.

27. Push the latch/latches to adjust to the appropriate position.

28. Holding the latch in this position, torque the latch screws to 5.6 Nm (50 in.lbs.).

29. Install the new U-shaped foam seals over the latch screws.

30. Install the top onto the vehicle.