Pavement Ends 44523 User Manual
Flip Top
Installation Instructions
www.pavement-ends.com
For: CJ7 1976 - 1986 Part Number: 44523
Wrangler/YJ 1986 - 1995
DO NOT INSTALL THIS PRODUCT ON ANY VEHICLE OTHER THAN THOSE LISTED ABOVE.
WARNING
This product is designed to enhance the appearance of the vehicle and to shield the occupants
from ordinary weather conditions. Do not rely in
any way on the components of this product to
contain occupants within the vehicle, or to protect
against injury or death in the event of an accident.
This product will not protect the occupants from
falling objects. Never operate vehicle in excess of
manufacturer’s specications.
WEAR SEAT BELTS AT ALL TIMES
Read and follow, precisely, all installation instructions provided when installing this product.
Failure to do so may result in a poor t and could
place occupants of the vehicle in a potentially
dangerous situation.
Installation Tips
Before you begin installing this product, read all
instructions thoroughly. Below are a few tips to
make this installation easier. After completing the
installation, keep these instructions for further
reference.
For a smooth t:
For ease in installation, the Flip Top should be
installed at temperatures above 72 ° F. Below this
temperature, the fabric may contract an inch or
more, making it dicult to t to the vehicle.
It is normal for the fabric to contract and wrinkle
when stored in the shipping carton. Within a few
days after the installation, the fabric will relax and
the wrinkles will disappear.
Rev. D 0210
Parts List and Hardware Identication
Top Fabric Qty - 1
Quarter Window, Rt Qty - 1
Quarter Window, Lt Qty - 1
Rear Windo Qty - 1
Windshield Header Tri Qty - 1
Zipper Pull Kit Qty -1
Windshield Header, Qty - 1,
Part Number 332.72
Windshield Bracket - Left, Qty - 1,
Part Number 332.01
Windshield Bracket - Right, Qty - 1,
Part Number 332.02
#8 x 1/2" Pan Head Washer Screw - Black,
Qty - 2, Part Number 200.48
Christmas Tree Fastener,
Qty - 12, Part Number 332.07
5/16" Black Washer, Qty - 12,
Part Number 233.04
Lock Nut, Qty - 2, Part
Number 316.94
5/16-18 Tapping Plate, Qty - 12, Part
Number 200.50
#10-15/16 Bolt, Qty - 2,
Part Number 326.85
#10 x 1/2" Pan Head Sheet Metal Screw,
Qty - 4, Part Number 1.92
#8 x 5/8" Screw, Qty - 4,
Part Number 278.13
Vertical Rod, Qty - 2,
Part Number 134.50
Corner Belt Rail, Left, Qty - 1,
Part Number 288.34
Bow Assembly - Left, Qty - 1,
Part Number 381.35
Corner Belt Rail, Right, Qty - 1,
Part Number 288.33
Bow Assembly - Right, Qty - 1,
Part Number 381.34
Side Belt Rail - Left, Qty - 1,
Part Number 134.02
5/16-18 x 1" Phillips Head Bolt,
Qty - 12, Part Number 236.20
Windshield Header Latch, Qty - 2,
Part Number 326.75
Side Belt Rail - Right, Qty - 1,
Part Number 134.01
Tailgate Bar, Qty - 1,
Part Number 288.75
44523 pg 2
Rev. D 0210
CJ7 Only - Wrangler Adjustment on next page
Tools Needed - CJ7
1/8", 5/32", 3/8" Drill Bits Flat Screwdriver
and Drill Motor Phillips Screwdriver
Center Punch Hammer
#40 Torx - Optional Pencil
hcnerW elbatsujdAtehctaR
Safety Glasses 10' Tape Measure
WARNING
Improper windshield adjustment will result in poor tting top and doors, causing
looseness or undue strain on the top.
Safety glasses should be worn at all
times while installing this product.
Caution
Note: If you are replacing an old soft top, be certain that all parts of the old top are removed, including the windshield
retainer. Old metal parts are not compatible with the new Supertop. Using parts other than those provided in your
Supertop kit can result in personal injury and/or damage to the vehicle and soft top.
Windshield Measurement
Before installing the top, check the windshield measurement.
The distance from the top lip of the windshield to the top outer
edge of the body must be 75 1/8" on both sides of the vehicle.
Measure 4"-6" inside the doors.
CJ7 Windshield Adjustment
If necessary, loosen the two screws in the Windshield Clamps at
the base of the windshield on each side of the vehicle. Adjust the
windshield forward or back, use a shim if needed to position the
windshield, and tighten the screws.
Windshield
Clamp Detail
Adjusting Screws Some Models may
require a #40 Torx
Step One
CJ7: After adjusting the windshield, install the Windshield
Brackets. If present, remove the outboard sun visor fasteners on
both sides of the windshield frame. Place the Windshield
Brackets ush with the frame on the upper corners of the
windshield. Use the bracket as a template to mark, center punch
and drill two 5/32" holes for each bracket. Mount each bracket to
the windshield frame using two #10 x 1/2" Pan Head Sheet Metal
Screws. Reinstall sun visor brackets.
Windshield
Bracket
Sun Visor Mount #20 Torx bolt
#10 x 1/2" Pan Head
Sheet Metal Screws
Tape Measure
Measurement
Detail
Front
Top lip of
windshield
75 1/8"
44523 pg 3
Rear point of
measurement on body
Rev. D 0210
Wrangler Adjustment
WARNING
Improper windshield adjustment will result in poor tting top and doors, causing looseness or undue strain
on the top.
Note: Under most circumstances, the windshield of the Wrangler will not require any adjustment. If your Wrangler windshield should require
adjustment, this adjustment should be performed only by an authorized automotive mechanic using a special "Tamper-Proof" Torx head tool.
Windshield Measurement
Before installing the top, check the windshield measurement. The distance
from the top lip of the windshield to the top outer edge of the body must be 75
1/8" on both sides of the vehicle. Measure 4"-6" inside the doors.
Wrangler YJ Windshield Adjustment
If necessary, loosen the #40 TORX bolts in the windshield clamps to loosen the
windshield in order to slip the bracket under the horizontal tube.
Reinstall the bolts that secure the
WARNING
Horizontal Sport Bars to the windshield with a torque of 17.0 ft. lbs.
each. If you do not have a torque
wrench these bolts should be
tested by a qualied mechanic
using a torque wrench. Failure to
tighten and test the torque of
these bolts can result in personal
injury or loss of life to the driver
and occupants of the vehicle in
the event of an accident.
1/8", 7/32", 3/8" Drill Bits #35 Torx - Optional Phillips Screwdriver
and Drill Motor #40 Torx - Optional Hammer
Center Punch #45 Torx - Optional Adjustable Wrench
Pencil Flat Screwdriver Ratchet
#20 Torx - Optional 10' Tape Measure Safety Glasses
Measurement
Detail
Front
Step One
Tools Needed- Wrangler
Tape Measure
Top lip of
windshield
#40 TORX Bolts
#45 TORX Bolt
Wrangler/YJ: Use a #20 Torx to remove the outboard sun visor
fasteners on both sides of the windshield frame. Remove the
two #40 Torx head bolts that secure the horizontal sport bar to
the windshield frame. Slide the Windshield Brackets between
the windshield and the horizontal sport bar mounts.
Reinstall the Torx head bolts, starting each in the frame with
your ngers. After the Torx head bolts are started by hand,
tighten with your rachet and Torx drive tool. Do not lay this tool
aside until both bolts are completely tightened. If you tighten
one of these bolts and the telephone rings - LET IT RING.
NEVER LAY THIS TOOL ASIDE OR INTERRUPT THIS PROCEDURE. This procedure should be followed carefully on both
sides of the vehicle.
Remove #40 TORX Bolts
Horizontal Sport
Bar
Sun Visor Mount #20 Torx bolt
Windshield
Windshield
Bracket
Sun Visor
Slide Windshield
Bracket between
Windshield and the
Sport Bar Mount
75 1/8"
Caution
Safety glasses should be worn at all
times while installing this product.
Rear point of
measurement on
body
44523 pg 4
Rev. D 0210
Step Two
INSTALL CHRISTMAS TREE FASTENER
If you have removed an old Bestop
top and windshield retainer, install a
Christmas Tree Fastener in each hole
in the windshield frame.
Christmas Tree Detail
Cross Section
Front of Vehicle
Christmas Tree
Fastener
Windshield Frame
Front of
Vehicle
Christmas
Tree Fasteners
Windshield
Step Three
INSTALL BELT R AILS
Install the Left and Right Side Belt
Rails on each side of the vehicle. Use
the existing holes, four 5/16" TORX
Bolts and four Tapping Plates on each
side. Use a #35 TORX Socket to install
the TORX Bolts.
Side Belt Rail Detail
Cross Section
Side Belt Rail
Tapping Plate
Inside of Vehicle
Body Panel
44523 pg 5
5/16" TORX
Bolt
Side Belt
Rail
Sport Bar
Front
5/16" TORX Bolt
Sport Bar
Rev. D 0210
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