Pavement Ends 44523 Flip Top - Manual (Page 4)

44523 pg 4
Rev. D 0210
Wrangler Adjustment
Tools Needed- Wrangler
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
WARNING
Note: Under most circumstances, the windshield of the Wrangler will not require any adjustment. If your Wrangler windshield should r equire
adjustment, this adjustment should be performed only by an authorized automotive mechanic using a special "Tamper-Proof" Torx h ead tool.
Improper windshield adjustment will result in poor fitting top and doors, causing looseness or undue strain
on the 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.
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. #45 TORX Bolt
#40 TORX Bolts
75 1/8"
Front
Measurement
Detail
Top lip of
windshield
Tape Measure
Rear point of
measurement on
body
Safety glasses should be worn at all
times while installing this product.
Caution
Reinstall the bolts that secure the
Horizontal Sport Bars to the wind-
shield with a torque of 17.0 ft. lbs.
each. If you do not have a torque
wrench these bolts should be
tested by a qualified 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.
Windshield
Bracket
Slide Windshield
Bracket between
Windshield and the
Sport Bar Mount
Sun Visor Mount -
#20 Torx bolt
WARNING
Step One
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 fingers. 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 PROCE-
DURE. This procedure should be followed carefully on both
sides of the vehicle.
Windshield
Sun Visor
Horizontal Sport
Bar
Remove #40 TORX Bolts