Page 1
Replay Top
w/ Tinted Side and Rear
Windows and Upper Door Skins
Installation Instructions
For: Jeep Wrangler (TJ) 2003-2006
Part Number: 51138
51138 pg 1
Table of Contents
FABRIC REPLACEMENT TOP PARTS LIST ............... PAGE 2
F
ABRIC REPLACEMENT TOP TOOLS NEEDED .......... PAGE 2
ABRIC REPLACEMENT TOP INSTALLATION ............. PAGE 2
F
F
ABRIC REPLACEMENT TOP WARRANTY ................ PAGE 10
1206 Rev. C
Page 2
Tools Needed
Phillips Screwdriver
Razor Knife
Fabric Top Qty - 1
Quarter Window, Right Qty - 1
Quarter Window, Left Qty - 1
Rear Window Qty - 1
Door Cover, Right Qty - 1
Door Cover, Left Qty - 1
Step One
REMOVE QUARTER WINDOWS AND REAR WINDOW
Remove the Quarter Windows and the Rear Window. Remove the metal Tailgate Bar from the bottom
of the Rear Window and set it aside.
Release the plastic strip sewn to the top above the
doors. Pull down and out to slip the plastic out of the
channel.
Release Plastic Strips
from Retainers
Parts List
Step Two
RELEASE WINDSHIELD LATCHES
Release the latch that secures the header to the
windshield. Pull up on the lever and then down
and out to release the hook from the slot in the
windshield frame.
Header
Latch
Windshield
Frame
Pull lever up
Release hook
from slot
Step Four
UNSNAP REAR BOW
Unsnap the fabric from the rear
bow and allow the bow to drop
onto the tailgate.
Step Three
RELEASE REAR CORNERS
Release the rear corners of the top. Pull gently
down and then out to release the plastic strip from
the retainer on the vehicle.
Unsnap the fabric
from the rear bow
51138 pg 2
Pull down and then out
to release the fabric from
the retainer
1206 Rev. C
Page 3
Step Five
UNFASTEN CENTER BOW
Unfasten the fl ap around the Center Bow.
Unfasten hook and
loop to unwrap fl ap
Sport Bar
View from inside vehicle
Center Bow
Step Six
REMOVE CORNER SCREWS
Collapse the bow assembly down onto the tailgate.
With the bow assembly laying on the tailgate, remove
the screws that fasten the fabric to the corners of the
header. Set the screws aside for use in installing the
new top fabric.
Remove Screw
Header
Detail of Header
Collapse bows and
fabric onto tailgate
Step Seven
REMOVE SCREWS HOLDING FABRIC TO HEADER
Flip the top fabric back over into the rear of the
vehicle (so that the fabric lays backing side up) to
expose the plastic strip along the edge of the fabric.
Remove the eight or fourteen screws that secure the
fabric to the header. Set the screws aside for use in
installing the new top. Then remove the old top fabric
from the vehicle.
NOTE: Due to a recent header assembly modifi cation by Daimler Chrysler, the plastic strip on the windshield header may have 8 screw locations instead of
14. Both attachment numbers of screws will securely
fasten the header and perform as the original design
was intended.
51138 pg 3
Flip the fabric into the
rear of the vehicle
Remove the 8 or 14 screws that
secure the fabric to the header
1206 Rev. C
Page 4
Step Eight
INSTALL TOP FABRIC ON HEADER
In order to install the top fabric, make sure that the
Center and Rear Bows are in the folded down position on the rear of the vehicle.
Lay the top fabric, backing side up in the rear of the
vehicle with the plastic strip facing up and aligned
with the front edge of the header. Locate the round
hole that marks the center of the plastic strip (all
other holes are slotted). Install a screw in the round
hole to secure the fabric to the header as well as to
center the top. Then proceed to install screws in the
remaining seven or thirteen holes along the front of
the header.
Lay fabric, backing
up in rear of vehicle
Start with center
ROUND hole
Step Nine
INSTALL CORNER SCREWS
Flip the fabric over so that it wraps around the
header and drape the top fabric over the tailgate.
Raise the header slightly and work the pockets in
the fabric over the corners of the header. Install
an oval head screw in each corner to secure the
fabric to the header.
Plastic Strip along
front edge of fabric
Detail of Center
Screw Hole
Plastic
Strip
Header
Align fabric
with header
Fabric
Start with center
ROUND hole
Tailgate
Detail of Header
Install Screw to
secure fabric
Header
Work pockets over
corners of header
Drape fabric over tailgate
51138 pg 4
1206 Rev. C
Page 5
Step Ten
SNAP TOP TO REAR BOW
Raise the header and bow assembly toward the
windshield and into position.
Inside the top, snap the fabric to the Rear Bow
(six snaps).
Snap fabric to Rear Bow
Step Twelve
SECURE REAR CORNERS
Make sure that the Center Bow is centered in the
hook and loop fl ap inside the top. Do not fasten the
fl ap at this time.
Pull down gently on the Rear Bow and work the
plastic sewn to the rear corners of the top into the
retainer on the vehicle.
Step Eleven
SECURE HEADER TO WINDSHIELD
Close the header latches to secure the front of the top to the windshield. Catch
the hook in the slot in the windshield frame and then close the lever over it so
that it lays fl at against the windshield frame.
Header Latch
Windshield
Frame
Windshield
Close lever over top of hook to
lay fl ush with windshield frame
Catch hook
in slot
Pull down gently
on the Rear Bow
and slip plastic into
retainer
Step Fourteen
ATTACH QUARTER PANEL ZIPPERS
Locate the left and right Quarter Panels and orient
them with the zipper along the top and rear of the
panel. Start the zipper at the front top corner of
the Quarter Panel, next to the door. Hold the end
of the zipper and close the zipper slider 10" - 12"
along the top of the panel.
Detail of Quarter
Panel
Hold end of
zipper while
starting slider
Start zipper at front
and close 10" - 12"
Step Thirteen
SECURE CENTER BOW
Wrap the hook and loop fl ap inside the top
around the Center Bow and fasten it to itself.
Wrap fl ap around
bow and fasten
hook and loop
Sport Bar
View from inside vehicle
Center Bow
51138 pg 5
1206 Rev. C
Page 6
Step Fifteen
SECURE FRONT OF QUARTER PANELS
Roll the plastic along the front of the Quarter
Panel into the channel of the Door Surround
on the vehicle.
Roll Plastic Strip into
channel in retainer
Step Seventeen
SECURE QUARTER PANELS
Close the zippers on the Quarter Panels the rest of
the way to the lower rear corner of the panel.
Start at the rear and roll the plastic along the bottom
of the panel into the retainer on the vehicle. Then
fasten the hook and loop strips along the top and
rear of the panel to the top.
Step Sixteen
SECURE TOP ABOVE DOOR OPENINGS
Locate the two plastic strips sewn to the sides of
the top, above each door. Slip the strips into the
channel in the Door Surround above the door opening. It is easiest to insert the front plastic strip into
the channel fi rst.
Roll Plastic Strips
into channel above
door opening
Fasten Hook and
Loop Strips
Close Zipper
Roll Plastic Strip into
channel in retainer
Step Eighteen
INSTALL TAILGATE BAR ON REAR WINDOW
Remove the Rear Window from the box and
lay it fl at with the backing side up. Locate the
Tailgate Bar set aside in Step One. The bar
has a “C” shaped channel, when viewed from
the end. Orient the bar with the round seal
down and slide the “C” channel on the retainer
onto the tubed strip sewn to the backing side
of the Rear Window.
Tailgate Retainer
Channel
Rear Window Backing Side
Tubed
Strip
Tailgate Bar
51138 pg 6
1206 Rev. C
Page 7
Step Nineteen
INSTALL TAILGATE BAR ON VEHICLE
Insert the Tailgate Bar into the mounts on each side
of the tailgate opening with the vinyl side of the Rear
Window toward the outside of the vehicle.
Place Tailgate
Bar in mounts
Step Twenty-one
SECURE REAR WINDOW FLAPS
Inside the top locate the fl aps sewn to the top on
each side of the rear window opening. Pull the fl aps
over to cover the zipper and tuck them in.
Step Twenty
SECURE REAR WINDOW ZIPPERS
To start the zipper, pull the two sliders as far down as possible
on the driver’s side of the window in order to catch the sliders
to the pin.
Once the zipper is caught, start the top slider 1/2". Then hold
up the top of the window with one hand and close the zipper
with the other. The zipper is sandwiched between layers of
fabric in the corners so be careful not to catch extra fabric in
the zipper. Close the zipper.
Make sure that the Tailgate Bar is centered and is securely in
the mounts. Then tuck the fl aps on the Rear Window under
the top fabric.
Tuck Flaps
under top
Start
Zipper
Rear Window
Pull fl ap over
to cover
zipper and
tuck in
View from inside top
Step Twenty-two
REMOVE OLD DOOR FABRIC
Remove the fabric upper doors from the vehicle.
Use a razor knife to cut the stitches on the old door
covers and take them off of the door frames
Pull both sliders down as far
as possible to catch pin
51138 pg 7
1206 Rev. C
Page 8
Do not pull on the weatherstrip to assist in getting the door cover on the door frame.
This will tear the weatherstrip and the door will not seal properly.
Step Twenty-three
INSTALL NEW DOOR FABRIC
Unzip the windows and separate the hook and loop fasteners on the door covers. Lay the door cover on a fl at smooth
surface with the outside facing down.
Start by working the lower rear corner of the door frame into the pocket in the lower rear corner of the cover. Then work the
lower front corner of the frame into the cover. Work the top front corner of the frame into the corner of the cover, between
the hook and loop fl aps (not between the zipper and the fl ap). Finally, use the tab sewn into the cover to work the last corner of the frame into the corner of the door cover, again between the hook and loop fl aps.
Make sure that the top edge of the door cover is straight along the top of the door frame. Work around the door fastening
the hook and loop strips tightly around the door frame. Once the door cover is on the frame, the tab in the top rear corner
of the cover may be cut off with a pair of scissors if desired.
NOTE: For the best results and to minimize scratches on the windows, remove all jewelry before installing the door covers.
NOTE: This door cover is designed to fi t very tight on the door frame. We recommend using a shoe horn to help work the
corners of the cover over the frame without tearing the fabric.
4. Use tab to install
Upper Rear Corner
Door Frame Between
Hook and Loop Flaps
3. Install Upper
Front Corner
Unzip Window
Detail of Hook and
Loop - Top of Door
1. Install Lower
Rear Corner
Detail of Hook and Loop Lower Front Corner
Hook and
Loop
Pull Flap
Up First
before installing
Hook and Loop
Step Twenty-four
REINSTALL DOORS
Reinstall the upper doors. Insert the pins into the grommets in the lower door.
Weatherstrip
2. Install Lower
Front Corner
51138 pg 8
1206 Rev. C
Page 9
Step Twenty-fi ve
TO FOLD THE TOP DOWN
REMOVE QUARTER PANELS AND REAR WINDOW
Remove the Quarter Panels and the Rear 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.
To roll up the Rear Window, remove the Tailgate Bar and open the zippers on each side of the window to the top. Start at the bottom
and roll the window to the inside. Avoid wrinkles in the fabric and window. Secure it in place with the elastic garters inside of the top.
When operating the vehicle without the Quarter Windows, the Rear Window should be rolled up and
secured with the elastic garters for proper ventilation.
Step Twenty-six
TO FOLD THE TOP DOWN
COLLAPSE TOP
Release the front of the top from the windshield. Raise the front of the deck
and collapse the rear bows, tucking the two plastic strips above the door
openings and the stay pad on the rear bow inside of the bows, Wrap the
fabric around the bows, then tuck the rear legs of the top under the bows.
Collapse bows and
fold toward rear
Tuck plastic
strips inside bows
Wrap fabric
around bows
Tuck stay pad
inside bows
Top Fabric
Wrap rear legs
under bows
51138 pg 9
1206 Rev. C
Page 10
Care and Maintenance of your New 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 fabric should be washed often using soap, warm water and a soft
bristle brush. Rinse with clear water to remove all traces of soap.
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: In the event of seeping through the seams, 3M Scotchgard® may be applied on the
inside of the seams to stop the seepage. 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.
LIMITED WARRANTY
We warrant our product to be free from defects in material and workmanship, for 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 “GOODS” MANUFACTURED BY OUR COMPANY: 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, please contact: Customer Service
877-638-9509
Normal Slider Jaws Parallel
Damaged Slider Jaws Spread Apart
(sometimes broken)
51138 pg 10
All or a portion of this product may have been made in China.
1206 Rev. C
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