Repair Procedure

The following service procedure outlines the installation of the complete top assembly which includes a two-ply fabric cover and a controlled linkage system that eliminates the need for the third bow assist springs and brackets.

Folding Top System Removal

1. Disconnect battery, remove headliner (save for reinstallation), and disconnect backlite wiring.

2. Remove rear seat cushion.

3. Remove seat back with quarter trims and seat belt retractors as an assembly.

NOTE: USE AN ASSISTANT TO HELP LIFT ASSEMBLY OUT OF VEHICLE.

4. Remove (2) screws on left rear side rail for backlite sensor assembly, using a 5/16 inch socket.
5. Remove (1) nut and cylinder bracket per side from studs using a 1/2 inch socket.

6. Loosen (1) bolt per side attached to top of cylinder rod using 1/2 inch socket. Do not completely remove cylinders from vehicle and save plastic bushings and inner washer for reuse.

7. Separate hydraulic cylinders from folding top rails.

8. Remove (4) nuts per side attaching the side tacking strips using 13 mm socket.

9. Remove side tacking strips from studs.

10. Remove (13) bolts attaching the rear tacking strip using a 13 mm socket.

CAUTION: SPRING BRACKET IS UNDER TENSION. DO NOT ALLOW TO SNAP BACK AFTER BOLT IS LOOSENED.

11. Remove rear tacking strip.

12. Remove (3) bolts per side from the pivot bracket using a 13 mm socket.

13. Release front latches and have assistant help lift off top assembly from car.

FIGURE 3:

Folding Top Assembly Installation

1. Carefully remove new top assembly from carton and have assistant help fasten the pivot brackets to the rear quarter mounting area.

NOTE: THIS STEP IS CRITICAL TO INSURE PROPER ALIGNMENT OF THE CONVERTIBLE TOP TO THE VEHICLE BODY. LOCATE PIVOT BRACKET TO QUARTER AREA KEEPING THE TWO HOLES AND SLOT CENTERED (SEE FIGURE 3).
2. Install pivot bracket bolts and torque to 250 +/- 50 inch pounds.

3. Raise top by hand and latch at header.

4. Install hydraulic cylinders to new top over studs, keeping hoses toward front of car.

5. Install one nut and cylinder bracket per side to studs and torque nut to 200 +/- 30 inch pounds.

6. Install plastic bushings and washer inside top of cylinder rods.

7. Install one bolt per side at top of cylinder rod and torque to 250 +/- 50 inch pounds.
8. Attach side tacking strips and install (4) nuts per side using a 13 mm socket and torque nuts to 250 +/- 50 inch pounds.

9. Attach rear tacking strip and install (13) bolts using a 13 mm socket.

NOTE: THE TOP WILL BE UNDER CONSIDERABLE TENSION AT THIS POINT. USE CARE NOT TO STRIP THE FASTENERS AND TIGHTEN BY STARTING FROM THE CENTER AND MOVE OUTWARD. TORQUE BOLTS TO 250 +/- 50 INCH POUNDS.

10. Install backlite sensor with (2) screws on left rear side and torque to 35 +/- 10 inch pounds. Attach wires to backlite.

FIGURE 4:

11. Partially fold back top and apply brush on adhesive (Mopar K-101 Cement) to rear rail seal surface (Figure 4).

12. Wrap folding top flap around rear rail.

13. Remove rear rail seal retainers from old top and install with (4) screws per side.

FIGURE 5:

14. Remove and install the (10) rubber screw protectors (see Figure 5). Place on (1) upper and (2) lower, rear rail and (2) rear, center rail screw tips on each side.

FIGURE 6:

15. Remove and install the tension cable bracket and spring keeping the bracket in a straight line (Figure 6) while tightening.

16. Latch top at front header and install headliner.

17. Cycle top at this time to test operation and fit.

18. Install quarter trim and rear seat assembly along with seat belt retractors.

19. Install rear seat cushion.

20. Cycle top and test for proper operation.
POLICY: Reimbursable within the provisions of the warranty


TIME ALLOWANCE:
Labor Operation No. 23-05-01-90 . . . . . . . . . 4.3 Hrs.


FAILURE CODE: X2 - Split Cut or Torn