Page 1
Flip Top with Upper
Half Doors
www.pavement-ends.com
For: Wrangler TJ 1997 - 2006 Part Number: 44587
Installation Instructions
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.
44587 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
Side Curtain, Rt. Qty - 1
Side Curtain, Lt. Qty - 1
Rear Curtain Qty - 1
Zipper Pull Kit Qty - 1
Right Upper Door Qty - 1
Left Upper Door Qty - 1
Windshield Header, Qty - 1,
Part Number 381.31
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 - 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" TORX Bolt,
Qty - 6, Part Number 236.20
Tailgate Retainer Mount, Left,
Qty - 1, Part Number 311.85
Vertical Rod, Qty - 2,
Part Number 134.50
Bow Assembly - Right, Qty
- 1, Part Number 381.36
Bow Assembly - Left, Qty - 1,
Part Number 381.37
Tailgate Retainer Mount, Right,
Qty - 1, Part Number 311.86
Side Belt Rail - Right, Qty - 1,
Part Number 381.32
Side Belt Rail - Left, Qty - 1,
Part Number 381.33
Tailgate Bar, Qty - 1,
Part Number 288.76
44587 pg 2
Rev. H 1210
Page 3
Step One
INSTALL WINDSHIELD BRACKETS
Loosen the Top Molding Screw on the A Pillar Molding attached to each side of the windshield. With a #40 Torx Driver, remove the outboard bolt that attaches the Sport Bar to
the Windshield. Slide the Windshield Bracket behind the A
Pillar Molding and fasten the bracket to the Windshield with
the bolt you removed. Re-tighten the top Molding screw.
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
Windshield
Bracket
A Pillar Molding
Top Molding
Screw
Sport Bar
Windshield
Caution
Safety glasses should be worn at all
times while installing this product.
#40 TORX
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 TORX
Bolts and three 5/16"-18 Tapping Plates
on each side. Use a #35 TORX Socket to
install the TORX Bolts.
Side Belt Rail Detail
Cross Section
Tapping Plate
Inside of Vehicle
Body Panel
44587 pg 3
Side Belt
Rail
5/16" TORX
Bolt
Side Belt Rail
Sport Bar
Front
5/16" TORX 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.
Tailgate Retainer
Mount (Left)
#8 x 1/2" Pan Head
Washer Screws
Place T ailgate
Mount fl ush with
edge of opening
Tailgate Opening
44587 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.
Push buttons in
Front Bow
Foam
Rear Bow
Slide Bow
Halves T ogether
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
Note: It may be helpful to have two people to slide both sides of the
bow assembly forward at the same time.
Side Belt Rail
Inside of Vehicle
44587 pg 5
Rev. H 1210
Page 6
Step Six
INSTALL VERTICAL ROD
Place the bottom of the Vertical Rod into the hole
at the front of the Side Belt Rail.
Front Bow
Vertical Rod
Place Vertical Rod
into hole
Rear
Bow
Side Belt Rail
Step Seven
INSTALL HORIZONTAL ROD
Slip the end of the Horizontal Rod into the tube on the Windshield Bracket. Push the
fi rst Spring Button through the tube until the second Spring Button on the rod pops up
through the hole in the Windshield Bracket.
Slide rod into bracket
until 2nd pin pops up
Horizontal Rod
Vertical Rod
Horizontal
Rod
Windshield
Bracket
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
44587 pg 6
Rev. H 1210
Page 7
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 by starting at the center and working your way out. Press the plastic retainer
along the front of the top into the channel on the header until it snaps into the channel. The ends of the plastic retainer extend
about 1/2" over each side.
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.
Tip: if you have trouble with attaching the retainer, move the header assembly to a 90° angle and try again.
Step Ten
SNAP TOP TO BOWS
Drape the top over the rear of the vehicle and snap it to
the bows.
Snap to bows
Note: Make sure the spreaderbars are in a lowered position.
This will ease installation.
Bows
View from inside top
Step Eleven
POSITION FRONT BOW
Push front support bow fi rmly all the way forward. The
clearance between the Sport Bar and Front Bow may
be tight.
Vertical
Rod
Front Support
Bow
44587 pg 7
Front
Bow must slip
into notch in belt
rail
Sport Bar
Rev. H 1210
Page 8
Step Twelve
SECURE REAR CORNERS
Insert the rear corners of the top into
the Rear Corner Retainers. Make sure
the front header is not latched.
Rear Corner
Retainer
Fabric
Plastic Strip
Edge of Plastic
Strip must line
up with edge of
retainer
Plastic Strip
under retainer
Rear Corner
Retainer
Plastic Strip under retainer
Plastic Reinforcement not
caught under retainer
Rear of Vehicle
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
44587 pg 8
Rev. H 1210
Page 9
Step Fourteen
POSITION SPREADER BARS
Push in the two snap buttons
on the spreader bar and
raise the bar into position.
Release the snap buttons to
lock the bar in place.
Step Fifteen
INSTALL SIDE CURTAINS
Start the top and rear zippers on the Side Curtains 2-3
inches.
Side
Curtain
Zipper under fl ap
Start top and
rear zippers
Spreader
Bar
Step Sixteen
INSTALL SIDE CURTAINS
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.
Hook and Loop Fastener
Front Bow
Front
Sport
Bar
Vertical
Retainer
View from inside vehicle - Driver's Side
Step Seventeen
INSTALL SIDE CURTAINS
Slip the plastic strip on the bottom of the Side Curtain 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
Plastic
Strip
work along it to
the other end.
44587 pg 9
Rev. H 1210
Page 10
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 zippers.
Slip Plastic Strip under
Corner Retainer
Tailgate
must be
open
Rear Corner
Retainer
Rear Curtain
44587 pg 10
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
Rear Corner
Retainer
Tube on inside of
Rear Curtain
Plastic
Strip
Rev. H 1210
Page 11
Step Twenty
INSTALL DOORS
Separate the hook and
loop fasteners on the door
covers and slide the new
cover onto the frame,
starting at the bottom front.
Work from corner to corner,
wrapping the fabric around
the frame and fastening
the hook to the loop as you
work around the door.
Step Twenty-one
INSTALL DOORS
Reinstall the upper doors. Insert
the pins into the grommets in the
lower door.
Pins
WARNING
Side
Curtain
When operating the vehicle without the Side Curtains, the
Rear Curtain should be rolled up for proper ventilation.
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.
Grommets
Adjusting the Top
Side Curtains
To remove the Side Curtains.
Unzip the rear and top zippers.
Release the plastic strip from
the retainer. Release the Hook
and Loop Fasteners from
around the Vertical Retainer.
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 in-
sert the plastic strip into the Side Belt Rail. Never operate the vehicle with the fabric
removed and the hardware in the fully erected position.
44587 pg 11
Rev. H 1210
Page 12
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 zipper 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 broken)
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
(877)638-9509
All or a portion of this product may have been produced in China.
44587 pg 12
Rev. H 1210
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