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Full Open Retractable Roof, Power: Cable: Removal

GC0157700Courtesy of CHRYSLER GROUP, LLC
  1. Remove the folding top cover (1) and place on a clean dry surface. Refer to COVER, HEADER, REMOVAL .
    GC0153695Courtesy of CHRYSLER GROUP, LLC
  2. On the interior side being serviced, turn the coat hook (1) a quarter turn and pull straight out to remove.
    GC0153216Courtesy of CHRYSLER GROUP, LLC
  3. Remove the sun visor. Refer to VISOR, REMOVAL .
    GC0153211Courtesy of CHRYSLER GROUP, LLC
  4. If servicing the passenger side, remove the grab handle. Refer to HANDLE, GRAB, REMOVAL .
    GC0153530Courtesy of CHRYSLER GROUP, LLC
  5. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, unclip the headliner side rail (2) and reposition out of the way.
    GC0157805Courtesy of CHRYSLER GROUP, LLC
  6. If servicing the passenger side, drill out the four rivets securing the grab handle bracket (1). Remove the grab handle bracket.
    GC0157680Courtesy of CHRYSLER GROUP, LLC
  7. On the interior of the vehicle on the bottom of the frame (2), remove the push pin fastener (1) securing the front rail trim.
    GC0157745Courtesy of CHRYSLER GROUP, LLC
  8. Using trim stick (special tool #C-4755, Trim Stick) (2) or equivalent, disengage the front rail cover (1) by prying up the outboard edge of the cover and rolling the rail cover inward.
    GC0157917Courtesy of CHRYSLER GROUP, LLC
  9. Remove the trim lace in the area of the wind deflector.
  10. Place a flat bladed tool between the wind deflector mounting bracket (1) and the wind deflector arm (2) and pry inboard to separate.
  11. Recover the washer/bushing (3).
  12. Repeat on the opposite side.
  13. Reposition wind deflector onto the windshield.
    GC0157788Courtesy of CHRYSLER GROUP, LLC
  14. Remove the front fastener (1) securing the rail (2) to the frame.
    GC0157614Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The battery should already be disconnected from the folding top cover removal. Check to be certain the battery negative cable is disconnected prior to performing the following steps.

  15. At the rear of the vehicle, remove the two fasteners (1) securing the rear of the side curtain airbag.
  16. Remove the side curtain air bag from the rear mounts and reposition.
    GC0157652Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Caution- Although there is clearance between the drill bit and side curtain air bag, exercise caution.

  17. Inside the vehicle using a drill (1) equipped with a 4 mm (5/32 in.) drill bit, drill out seven rivets securing the rail to the frame (2). Start at the A-pillar and drill out the first two steel rivets and continue working back, drilling out the next four aluminum rivets.
    GC0157811Courtesy of CHRYSLER GROUP, LLC
  18. Drill out the next rivet and remove the rail spring (2) and roller (1).
    GC0157742Courtesy of CHRYSLER GROUP, LLC
  19. Lift the rail (1) and wedge a 0.5" x 2" in block of wood (2) or equivalent, under the rail.
    GC0157860Courtesy of CHRYSLER GROUP, LLC
  20. Lift up on the front of the wind deflector mounting bracket (1) and unclip it from the rail (2).
    GC0153472Courtesy of CHRYSLER GROUP, LLC
  21. Inside the rear of the vehicle, using a drill equipped with a 5 mm (13/64 in.) drill bit, drill out the four rivets (1) securing the motor cover plate (2).
  22. If necessary, use a hammer and chisel to remove the heads of the rivets.
  23. Remove the motor cover plate (2)
    GC0153471Courtesy of CHRYSLER GROUP, LLC
  24. Disconnect the electrical connector from the motor (2) and the module (1).
    GC0157746Courtesy of CHRYSLER GROUP, LLC
  25. Remove the three fasteners (1) securing the folding top cover motor (2) to the rear shelf.
  26. Remove the motor.
    GC0157849Courtesy of CHRYSLER GROUP, LLC
  27. Inside the rear of the vehicle with the use of a trim tool (3), remove the eight push pin fasteners (1) securing the bottom rear shelf trim panel (2) to the rear shelf.
  28. Remove the bottom rear shelf trim panel (2) from the vehicle.
    GC0157605Courtesy of CHRYSLER GROUP, LLC
  29. Under the rear shelf, remove the two fasteners (2) from manual drive gear plate.
  30. Remove the plate and 17 mm hex head manual drive gear.
    multimedia:A supplement to the article is available.
  31. Slide the lifting arm all the way forward until it stops.
  32. See video above for the following steps.
    GC0157905Courtesy of CHRYSLER GROUP, LLC
  33. Remove the front stop block through the bottom of the rail
  34. Slide the lifting arm all the forward until it stops.
    GC0157858Courtesy of CHRYSLER GROUP, LLC
  35. Press the release tab and carefully slide the mechanism out the front of the rail.
  36. Take care not to loose any of the mechanism pieces as it comes out the front of the rail.
    GC0157718Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Actual parts are colored and grease removed for demonstration purposes only.

  37. Disconnect the cable (3) from the driven sledge (2).
  38. Remove the lifting arm assembly (1) and driven sledge from the rail.
    GC0157886Courtesy of CHRYSLER GROUP, LLC
  39. Run a pick within the rail to remove any large rivet debris.
  40. Use compressed air to blow out the tracks.
  41. Wet a small piece of clean rag (2) with alcohol or acetone.
  42. Fold the rag and insert it into the rail channel.
  43. With the use of a pick (1) or equivalent, run the rag through the front of the channel and out the rear of the rail.
  44. Repeat the cleaning steps several times to be certain all debris has been removed.
  45. Pull the cable completely out of the rail.
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