Page 1
Flip Top
Installation Instructions
www.pavement-ends.com
For: Wrangler TJ 1997 - 2006 Part Number: 44527
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 specifi cations.
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 fi t and could
place occupants of the vehicle in a potentially
dangerous situation.
44527 pg 1
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 fi 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 diffi cult to fi 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. H 1210
Page 2
Parts List and Hardware Identifi cation
Top Fabric Qty - 1
Quarter Window, Rt. Qty - 1
Quarter Window, Lt. Qty - 1
Rear Window Qty - 1
Windshield Header Trim Qty - 1
Windshield Header, Qty - 1,
Part Number 381.31
#8 x 1/2" Pan Head Washer Screw - Black,
Qty - 4, Part Number 200.48
#10-15/16 Bolt, Qty - 2,
Part Number 326.85
5/16" Black Washer, Qty - 6,
Part Number 233.04
Lock Nut, Qty - 2, Part
Number 316.94
5/16-18 Tapping Plate, Qty - 6,
Part Number 200.50
5/16-18 x 1" Phillips Bolt, Qty - 6,
Part Number 236.20
Windshield Bracket - Left,
Qty - 1, Part Number 380.97
Vertical Rod, Qty - 2,
Part Number 134.50
Tailgate Retainer Mount, Left,
Qty - 1, Part Number 311.85
Windshield Bracket - Right,
Qty - 1, Part Number 380.96
Tailgate Retainer Mount, Right,
Qty - 1, Part Number 311.86
Bow Assembly - Right, Qty - 1,
Part Number 381.36
Bow Assembly - Left, Qty - 1,
Part Number 381.37
Side Belt Rail - Left, Qty - 1,
Part Number 381.33
Side Belt Rail - Right, Qty - 1,
Part Number 381.32
Tailgate Bar, Qty - 1,
Part Number 288.75
44527 pg 2
Rev. H 1210
Page 3
Step One
INSTALL WINDSHIELD BRACKETS
Loosen the top screw on the A Pillar Molding. Use a #40 TORX
Driver to remove the outboard bolt that attaches the Sport Bar
to the windshield. Slide the Windshield Bracket behind the A
Pillar Molding and reinstall the bolt you removed to secure the
bracket to the windshield. Re-tighten the top molding screw.
Windshield
Bracket
Tools Needed
1/8" Drill Bit Flat Screwdriver
and Drill Motor Phillips Screwdriver
Center Punch Hammer
#35 Torx Pencil
#40 Torx Adjustable Wrench
Ratchet Safety Glasses
A Pillar Molding
Top Molding
Screw
Sport Bar
Windshield
#40 TORX
Caution
Safety glasses should be worn at all
times while installing this product.
Step Two
INSTALL BELT RAILS
Install the Left and Right Side Belt
Rails on each side of the vehicle.
Use the existing holes, three 5/16"18 x 1 Phillips Bolts and three
5/16"-18 Tapping Plates on each
side.
Side Belt Rail Detail
Cross Section
Tapping Plate
Inside of Vehicle
Body Panel
44527 pg 3
5/16" Phillips Bolt
Side Belt
Rail
Side Belt Rail
Sport Bar
Front
5/16" Phillips Bolt
Sport Bar
Rev. H 1210
Page 4
Caution
When drilling in the top edge of the vehicle body, check underneath for
wiring for the rear lights. Pull the wiring out of the way before drilling.
Step Three
INSTALL THE TAILGATE RETAINER MOUNTS
Locate the left and right Tailgate Retainer Mounts. Place the mounts fl ush with the edge of the tailgate opening.
Install the Tailgate Retainer Mounts with two #8 x 1/2" Pan Head Washer Screws for each mount.
If your vehicle does not have holes at this location, align the Tailgate Retainer Mounts fl ush with the edge of the
tailgate opening. Then mark the locations of the holes in the mounts, center punch and drill a 1/8" hole at the
marked locations. Install the mounts with two #8 x 1/2" Pan Head Washer Screws for each mount.
Place T ailgate
Tailgate Retainer
Mount (Left)
#8 x 1/2" Pan Head
Washer Screws
Mount fl ush with
edge of opening
Tailgate Opening
44527 pg 4
Rev. H 1210
Page 5
Step Four
ASSMEBLE BOW ASSEMBLY
Assemble the two halves of the support bow. Orient the two pieces to each other and lay them on the fl oor. Slide the pieces to-
gether, pushing down on the buttons. Once the two halves are together install a Snap Head Screw in the hole formed in the center,
front of each bow. This will require a #20 TORX socket.
Push buttons in
Front Bow
Slide Bow
Halves T ogether
Foam
Rear Bow
Foam
Slide halves together to form
Support Bow Assembly
Note: It may be helpful to use a fl at screwdriver to push buttons down while sliding bow halves together.
Step Five
INSTALL BOW ASSEMBLY
Slide the ends of the front and rear bows into the tracks in the Side
Belt Rails on each side of the vehicle. Start from the rear of the vehicle
and slide the bow assembly toward the front.
Front Bow
Rear Bow
Slide Bow Ends
into Track
Side Belt Rail
Inside of Vehicle
Note: It may be helpful to have two people to slide both sides of the
bow assembly forward at the same time.
44527 pg 5
Rev. H 1210
Page 6
Step Six
INSTALL HORIZONTAL ROD
Slip the end of the Horizontal Rod into the tube on the Windshield Bracket until the spring button on the rod pops
up through the hole in the Windshield Bracket.
Slide rod into bracket
until pin pops up
Windshield
Bracket
Horizontal Rod
Note: The pin must pop up through the hole in the Windshield Bracket for proper fi t.
Horizontal Rod
Vertical Rod
Step Seven
INSTALL VERTICAL ROD
Place the bottom of the Vertical
Rod into the hole at the front
of the Side Belt Rail. Bolt the
rod to the Horizontal Rod on
the Bow Assembly with the
Screw and Nut attached to the
Horizontal Rod.
44527 pg 6
Front Bow
Vertical Rod
Place Vertical Rod
into hole
Rear Bow
Side Belt Rail
Rev. H 1210
Page 7
Step Eight
INSTALL WINDSHIELD HEADER
Orient the Windshield Header
on the vehicle. Lay the header
on top of the bows with the snap
studs facing up. Place the legs
of the header into the bracket
above the door opening on each
horizontal rod. Install the legs in
the brackets with a #10-15/16
Bolt and Lock Nut on each side.
Front
Windshield
Header
Bracket
#10-15/16
Bolt
Lock Nut
Bracket
Step Nine
INSTALL TOP TO HEADER
Pull the deck up over the center bow to the Windshield Header Assembly. Open the Sun Roof and stand
inside the vehicle to access the front of the assembly. Wrap the front edge of the Top Fabric around the
front edge of the Windshield Header Assembly. Make sure that the fabric is centered on the header. Press
the plastic retainer along the front of the top into the channel on the header until it snaps into the channel.
Wrap Fabric around
Windshield Header and
snap plastic retainer into
channel in header
Note: Make sure the plastic retainer is snapped fi rmly into the Header channel. The Sun Roof feature will
not work properly if the retainer is not securely installed.
44527 pg 7
Rev. H 1210
Page 8
Step Ten
Bows
SNAP TOP TO BOWS
Drape the top over the
rear of the vehicle and
snap it to the bows.
Snap to bows
Step Eleven
POSITION FRONT BOW
Push the front support bow all the way forward. The bow
must slip into notch in belt rail.
Vertical
Rod
Front Support
Bow
View from inside top
Front
Bow must slip
into notch in
belt rail
Sport Bar
Step Twelve
SECURE REAR CORNERS
Insert the rear corners of the top
into the Rear Corner Retainers.
Rear Corner
Retainer
Fabric
Edge of Plastic
Strip must line
up with edge of
retainer
Rear Corner
Retainer
Plastic Strip under retainer
Plastic Reinforcement not
caught under retainer
44527 pg 8
Plastic Strip
Plastic Strip
under retainer
Rear of Vehicle
Rev. H 1210
Page 9
Step Thirteen
POSITION REAR SUPPORT BOW
Pull the bottom of the rear support bow back until it snaps into the notch in the side rail. Make sure that the zippers
are not caught or folded behind rear support bow and that the bow slips into the notch in the Side Belt Rail.
Rear Support Bow
Rear Support Bow
Push bow back
Bow must slip into
notch in belt rail
View from inside vehicle
Step Fourteen
POSITION SPREADER BARS
Push the spreader bars up until they snap into place.
Spreader Bar
44527 pg 9
Rev. H 1210
Page 10
Step Fifteen
INSTALL QUARTER WINDOWS
Start the top and rear zippers on the Quarter Windows
2-3 inches.
Quarter
Window
Zipper under fl ap
Start top and
rear zippers
Step Sixteen
INSTALL QUARTER WINDOWS
Slip the plastic strip on the bottom of the Quarter Window
into the Side Belt Rail. Close the top and rear zippers on the
side curtain.
Close
Zippers
Start at one end
of the strip and
Side Belt
Rail
Fabric
work along it to
the other end.
Step Seventeen
INSTALL QUARTER WINDOWS
Wrap fabric fl ap on the front of the side curtain around the Verti-
cal Rod (not the front bow) and fasten the hook and loop strips
to each other.
Front Bow
Hook and Loop Fastener
Front
Sport
Bar
Plastic
Strip
44527 pg 10
Vertical
Retainer
View from inside vehicle - Driver's Side
Rev. H 1210
Page 11
Step Eighteen
SECURE DOOR OPENING
Wrap the fl ap, sewn to the top above each door, around the
Horizontal Rod and fasten the hook and loop strips to each
other.
Front
Wrap Flap around
Horizontal Retainer
Windshield
Step Nineteen
INSTALL TAILGATE BAR
Open the tailgate. Orient the Rear Curtain Retainer with the rubber bulb facing down, in order to form a seal with the top of the
tailgate. Slide the groove in the Rear Curtain Retainer onto the tube inside the bottom of the Rear Curtain. Roll the Rear Curtain
Retainer into the top of the Corner Belt Rail. Slip the plastic on the bottom of the corners under the bottom of the Corner Belt Rail.
Close the rear curtain zipper.
Slip Plastic Strip under
Corner Retainer
Tailgate must
be open
Rear Corner
Retainer
Rear Curtain
Rear Curtain Retainer
Slide groove in Rear Curtain
Retainer onto tube on inside
of Rear Curtain. Push it into
Tailgate Retainer.
Rear Curtain Retainer Oriented with Rubber
Bulb Down
Tube on inside of
Rear Curtain
Rear Corner
Retainer
Plastic
Strip
44527 pg 11
Rev. H 1210
Page 12
Adjusting the Top
WARNING
When operating the vehicle without the Quarter Windows,
the Rear Curtain should be rolled up for proper ventilation.
Quarter Windows
Quarter
Window
To remove the Quarter Windows.
Unzip the rear and top zippers.
Release the plastic strip from the
retainer. Release the Hook and
Loop Fasteners from around the
Vertical Retainer.
Opening the Sun Roof
Release the Windshield Header Latches and fold the Windshield
Retainer back so that it rests on the center bow and the sport bar.
Removal of Soft Top for Open Air Driving
When operating the vehicle with the fabric top removed, it is very important that
the supporting hardware system be disconnected from the windshield bracket and
folded fl at to the rear of the vehicle. Wrap the elastic straps around the bows and
insert the plastic strip into the Side Belt Rail. Never operate the vehicle with the
fabric removed and the hardware in the fully erected position.
44527 pg 12
Rev. H 1210
Page 13
Care and Maintenance of your Flip Top
Your top is made of the fi nest materials available. To keep it looking new and for the
maximum possible wear, it will need periodic cleaning and maintenance.
Washing: The top fabric should be washed often using soap, warm water and a soft
bristle brush. Rinse with clear water to remove all traces of soap.
Windows: Keep windows clean to avoid scratching. DO NOT use a brush on the
windows! Wash with a watersoaked cloth or sponge and a mild dishwashing detergent.
NEVER WIPE THE WINDOWS WHEN THEY ARE DRY. Be careful when cleaning snow
or frost from the vinyl windows since they are easily scratched and may crack at low temperatures. DO NOT roll the sides or rear window in cold weather. The windows become
stiff and will crack.
Zippers: Keeping the zipper cleaned and lubricated with a silicone lubricant will help
prevent damage and keep the zippers in a smooth
working condition. If a zipper opens
behind the slider, the slider may
have been spread apart. This
problem can usually be repaired
by using an ordinary pair of
pliers to bring the sides back
into parallel. Return slider to the end of the
zipper in the normal Open position. Squeeze
lightly at fi rst and test the zipper. If the zip-
per continues to remain open squeeze more
fi rmly with the pliers and try the zipper again.
Repeat this procedure until the zipper operates correctly.
Water: Seeping through at the seams may be stopped by applying 3-M Scotchgard® on
the inside of the seams. Rips in the fabric may be repaired with Bondex® iron on patches. Iron the patches to the Inside of the top, carefully following the Bondex® instructions.
Snaps: Keep snaps cleaned and lubricated with silicone to help prevent snaps from
sticking to the studs. If a snap does become stuck to a stud, use a screwdriver and
GENTLY pry apart to prevent permanent damage to the snap or the top fabric.
Normal Slider
- Jaws Parallel
Damaged Slider
- Jaws Spread
Apart (sometimes
LIMITED WARRANTY
We warrant our product to be free from defects in material and workmanship, for the terms specifi ed below, provided there has been
normal use and proper mainte nance. This warranty applies to the original purchaser only. All remedies under this warranty are limited to
the repair or replacement of any item or items found by the factory to be defective within the time period specifi ed.
If you have a warranty claim, fi rst you must call our factory at the number below for instructions. You must retain proof of purchase
and submit a copy with any items returned for warranty work. Upon completion of warranty work, if any, we will return the repaired or
replaced item or items to you freight prepaid. Damage to our products caused by accidents, fi re, vandalism, negligence, misinstallation,
misuse, Acts of God, or by defective parts not manufactured by us, is not covered under this warranty.
THE WARRANTY TIME PERIOD IS AS FOLLOWS: ALL “SOFT GOODS” MANUFACTURED BY OUR COMPANY (USING PRIMARILY
VINYLS, PLASTICS, AND/OR FOAM): ONE YEAR FROM DATE OF PURCHASE.
ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE CREATED HEREBY
ARE LIMITED IN DURATION TO THE SAME DURATION AND SCOPE AS THE EXPRESS WRITTEN WARRANTY. OUR COMPANY
SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential
damages, so the above limitations or exclusions may not apply to you.
This warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state.
For further information or request for warranty work, please contact: Customer Service
800-845-3567
All or a portion of this product may have been produced in China.
44527 pg 13
Rev. H 1210
Loading...