Convertible Top Hydraulic Cylinder: Service and Repair
REMOVALREMOVAL - TONNEAU COVER CYLINDER
1. Disconnect the negative battery cable.
2. Remove the left side trunk trim panel.
NOTE: Do not disconnect the hydraulic lines from the pump assembly.
3. Partially remove the hydraulic pump assembly.
4. Remove the hydraulic line retainers and disconnect the lines from the cylinder (1).
5. Remove the travel sensor from the cylinder.
6. Remove the cylinder lower retainer (3) and remove the cylinder (1) from the pump bracket (2).
REMOVAL - MAIN CYLINDER
NOTE: Left side shown, right side similar.
1. Disconnect the negative battery cable.
2. Manually raise tonneau cover and support.
3. Remove the upper and lower cylinder retainers (2).
4. Remove the main cylinder (1) from the top frame assembly to gain access to the hydraulic lines and travel sensors.
5. Remove the hydraulic line retainers and remove lines from the cylinder.
6. Remove the travel sensors from the cylinder (left side only).
REMOVAL - REAR BOW CYLINDER
1. Disconnect the negative battery cable.
2. Manually lower the convertible top (3) into the storage area.
3. Secure the tonneau cover (2) in the upright position.
4. Remove the front cover retaining screws (1) and retainer (4).
5. Remove the front side weather strips (1).
6. Remove the cover to front bow retaining screws (1).
7. Manually place the top assembly in the upright position.
8. Remove the top cover from the front bow and fold back to gain access to the front cover retaining strap rivets (1).
9. Drill out the front cover retaining strap rivets (1) (one on each side) (left side shown, right side similar).
10. Disconnect both cover support cables (2) from the front bow (1) (left side shown, right side similar).
11. Remove the top support cable (1) from the cover (2) (left side shown, right side similar).
12. Remove the rear weather strip (1) from the cover side retainer (left side shown, right side similar).
13. Drill out the cover side retaining rivets (1).
14. Release the cover side retainers from the rear bow support by sliding the cover down and then out (left side shown, right side similar).
15. Disconnect the hydraulic lines (4) from the cylinder (2).
16. Remove the travel sensors from the rear bow cylinder (left side only).
17. Remove the upper and lower retainers (1 and 3) and remove the cylinder from the top frame assembly (right side shown, left side similar).
REMOVAL - CYLINDER TRAVEL SENSOR
NOTE: If a main cylinder or rear bow cylinder travel sensor is faulty, all of the main and rear bow cylinder travel sensors must be replaced.
1. Remove the plastic tie wrap (3) from the hydraulic cylinder.
2. Rotate the hydraulic line (1) on the hydraulic cylinder in order to gain access to the travel sensor.
NOTE: The travel sensor is retained by a pressed fit. To remove the travel sensor, grasp the sensor and gently pry the sensor from the hydraulic cylinder housing.
3. Remove the travel sensor (2) from the hydraulic cylinder.
INSTALLATION
INSTALLATION - TONNEAU COVER CYLINDER
1. Install tonneau cover cylinder (1) to pump bracket (2) and install the lower retainer (3).
NOTE: Be sure to use new retainers and O-rings when installing hydraulic lines to the cylinder.
2. Connect hydraulic lines to cylinder with new retainers.
3. Connect both travel sensors to the cylinder.
4. Install the hydraulic pump assembly.
5. Install the left side trunk trim panel.
6. Connect the negative battery cable.
INSTALLATION - MAIN CYLINDER
1. Install the travel sensors on the cylinder (left side only).
2. Connect the hydraulic lines to the cylinder with a new O-rings and retainers.
3. Position the main cylinder (1) into the top frame assembly and install the retainers (2).
4. Lower the tonneau cover manually and relatch the rear bow.
5. Connect the negative battery cable.
INSTALLATION - REAR BOW CYLINDER
1. Install the rear bow cylinder (2) into the top frame and install the retainers (1 and 3) (right side shown, left side similar).
2. Connect the travel sensors to the cylinder (4) (left side only).
3. Connect the hydraulic lines to the cylinder using new O-rings and retainers.
4. Install the cover side retainers to the top frame by sliding the retainer into the frame and pushing up to lock into place (left side shown, right side similar).
5. Install new retaining rivet (1) (left side shown, right side similar).
6. Install both rear side weather strips (1) (left side shown, right side similar).
7. Install the cover support cables (1) into the cover (2) (left side shown, right side similar).
8. Connect both of the front cover support cables (2) to the front bow (1).
9. Manually place the top in the upright position.
10. Attach the front cover retaining straps with new rivets (1) (one each side) (left side shown, right side similar).
11. Install the top to the front bow.
12. Lower the top assembly into the storage area.
13. Install the front bow side cover retainer screws (1) (left side shown, right side similar).
14. Install the front side weather strips (1) (right side shown, left side similar).
15. Install the front cover retainer (4) and retaining screws (1).
16. Lower tonneau cover down and manually lock into place.
17. Connect the negative battery cable.
INSTALLATION - CYLINDER TRAVEL SENSOR
1. Install the travel sensor (2) to the hydraulic cylinder.
NOTE: The travel sensor is retained by a pressed fit. To install the travel sensor, gently press the sensor into the hydraulic cylinder housing.
2. Rotate the hydraulic line (1) on the hydraulic cylinder, and tuck the line into the groove on the cylinder housing.
3. Tie wrap the hydraulic line to cylinder housing using a plastic tie wrap (3).