Roof Panel

ROOF PANEL

REMOVAL

1. Remove rear fascia.
2. Remove tail lamp closure panel.
3. Remove rear splash shields.
4. Remove quarter panels.
5. Remove headlining.
6. Remove liftgate, support cylinders, and liftgate hinges.
7. Remove door opening weatherstrip from weatherstrip retainers along roof panel.
8. Remove weatherstrip retainers from roof panel.
9. Remove A-pillar trim panel.
10. Remove fuel fill door.

Fig. 3:

11. Remove roof panel brackets along windshield surround header (Fig. 3).

Fig. 4:

12. Remove bolts attaching roof panel brackets to front of sport bar (Fig. 4).
13. Retrieve shims attaching bracket to sport bar.
14. Remove bolts attaching roof reinforcement cables to back of sport bar.

Fig. 5:

15. Remove nuts attaching roof panel to trunk pan from inside rear wheelhouse (Fig. 5).
16. Remove trunk rear trim panel.
17. Remove trunk lining as necessary to access roof panel nuts at rear of trunk area.
18. Remove nuts attaching roof panel to trunk pan at rear of trunk pan.
19. Drill out rivets attaching the roof to the trunk pan extensions.
20. Using a suitable cutting tool, cut the silicone sealing the roof panel to the trunk pan along the side and rear edges of roof.
21. Using a suitable cutting tool and cutting from inside of the vehicle, carefully and slowly, cut the urethane adhesive between the roof and the windshield surround.

CAUTION: When cutting the urethane between the roof and the windshield surround, the use of an aggressive or forceful cutting motion may cause the cutting tool to cut too deep and damage the windshield molding.

Fig. 6:

22. With aid of a helper, remove the roof panel from the vehicle (Fig. 6).

INSTALLATION

1. Clean silicone residue from trunk pan and roof panel.
2. Paint body panels as necessary prior to installation.
3. Using a razor knife, remove as much of the original urethane from the roof panel and the windshield surround.

CAUTION: Be careful not to cut into the roof panel or windshield surround.

4. Clean the roof panel and windshield surround with Mopar(R) Glass Cleaner, or equivalent, and lint-free cloth.
5. Loosely install the roof panel brackets to the windshield surround.

NOTE: If a new windshield surround or roof panel are being installed, do a preliminary fit of the components and make suitable marks to indicate where the urethane will be applied prior to applying the primers.

6. Apply clear glass primer 25 mm (l in.) wide along urethane surface of roof and surround panels and wipe with clean/dry lint-free cloth.
7. Apply black out primer 25 mm (1 in.) wide along urethane surface of roof and surround panels. Allow at least three minutes drying time.

CAUTION: Ensure that the same urethane that is specified in the Windshield section of this group is used.

8. Using an applicator which applies a triangular bead, apply a bead of urethane along the length of original urethane location on windshield surround.
9. Apply a bead of Mopar(R) RTV Silicone, or equivalent, on trunk pan where roof panel edge will mate to the trunk pan (Fig. 5)and (Fig. 6).
10. With aid of a helper, position roof panel to vehicle. Ensure that the front edge of the roof panel is positioned under the windshield molding and the studs at the rear of roof pass through the mating holes in trunk pan.

CAUTION: Minimize movement of the roof panel once it comes into contact with the urethane and silicone or water and/or air leaks may occur.

11. With a helper supporting the roof away from windshield surround, adjust roof brackets on windshield surround vertically until roof is flush to the windshield, Refer to Body and Frame / Specifications.
12. Install bolts attaching roof panel brackets to the roof panel.
13. Install nuts attaching rear of roof panel to the trunk pan.
14. Install nuts attaching sides of roof panel to the trunk pan from rear wheelhouse area.
15. Install bolts attaching roof panel brackets to front of sport bar.
16. Install retrieved shims from sport bar to bracket.
17. Install bolts attaching roof reinforcement cables to rear of sport bar.
18. Install rivets attaching roof to trunk pan extensions.
19. Install trunk lining.
20. Install trunk rear trim panel.
21. Install fuel fill door.
22. Install A-pillar trim panel.
23. Install weatherstrip retainers to roof panel.
24. Install door opening weatherstrip to weatherstrip retainers.
25. Install liftgate, support cylinders, and liftgate hinges.
26. Install headlining.
27. Install quarter panels.
28. Install rear splash shields.
29. Install tail lamp closure panel.
30. Install rear fascia.