Owner's manual

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44587 pg 1

Rev. H 1210

Flip Top with Upper

Half Doors

Installation Instructions

This product is designed to enhance the appear-

ance 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 in-

structions 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.

WARNING

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.

For: Wrangler TJ 1997 - 2006 Part Number: 44587

www.pavement-ends.com

Summary of content (12 pages)

PAGE 1
www.pavement-ends.com For: Wrangler TJ 1997 - 2006 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 specifications.
PAGE 2
Parts List and Hardware Identification Top Fabric Side Curtain, Rt. Side Curtain, Lt. Rear Curtain Zipper Pull Kit Right Upper Door Left Upper Door Qty - 1 Qty - 1 Qty - 1 Qty - 1 Qty - 1 Qty - 1 Qty - 1 #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 Windshield Header, Qty - 1, Part Number 381.31 5/16-18 Tapping Plate, Qty - 6, Part Number 200.
PAGE 3
Tools Needed 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.
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 flush 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.
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 floor. Slide the pieces together, pushing down on the buttons. Push buttons in Slide Bow Halves Together Front Bow Foam Foam Slide halves together to form Support Bow Assembly Rear Bow Note: It may be helpful to use a flat screwdriver to push buttons down while sliding bow halves together.
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 Rear Bow Place Vertical Rod into hole Side Belt Rail Step Seven INSTALL HORIZONTAL ROD Slip the end of the Horizontal Rod into the tube on the Windshield Bracket. Push the first Spring Button through the tube until the second Spring Button on the rod pops up through the hole in the Windshield Bracket.
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.
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.
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. Spreader Bar Step Fifteen INSTALL SIDE CURTAINS Start the top and rear zippers on the Side Curtains 2-3 inches.
PAGE 10
Step Eighteen SECURE DOOR OPENING Wrap the flap, sewn to the top above each door, around the Horizontal Rod and fasten the hook and loop strips to each other. Wrap Flap around Horizontal Retainer Front 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.
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.
PAGE 12
Care and Maintenance of your Flip Top Your top is made of the finest 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.