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Full Open Retractable Roof, Power: Cable: Installation

multimedia:A supplement to the article is available.
  1. If necessary build up a lifting arm assembly (1), watch video.
  2. Use white lithium grease to heavily coat the moving parts of the lifting arm assembly and the inner contact surfaces of the rail.
  3. Insert the cable into the front of the rail channel until approximately 75 mm (3 in.) of the cable is protruding out the front of the rail.
    multimedia:A supplement to the article is available.
  4. Lifting arm assembly into rail, watch video.
    GC0157718Courtesy of CHRYSLER GROUP, LLC
  5. Connect the cable end (3) onto the driven sledge (2).
  6. Insert lifting arm assembly (1), driven sledge (2) and cable (3) into the rail, take care not to loose any of the loose parts.
  7. Use a pick to push the driven sledge (2) back into the rail until it stops.
    GC0157858Courtesy of CHRYSLER GROUP, LLC
  8. From the opening in the inside of the rail, push the release arm on the side of the locking sledge.
  9. Push the lifting arm assembly back into the rail.
    GC0157905Courtesy of CHRYSLER GROUP, LLC
  10. Front stop block must be installed in proper direction and are not interchangeable from right to left. Position the stop block with the flat end facing the rear of the vehicle and the open side facing the exterior.
  11. Install the stop block through the opening in the bottom of the rail.
    GC0157860Courtesy of CHRYSLER GROUP, LLC
  12. Position the wind deflector mounting bracket (1) and insert it onto the rail (2).
  13. Inspect to be certain wind deflector mounting bracket (1) is positioned correctly and locked in place.
    GC0157742Courtesy of CHRYSLER GROUP, LLC
  14. Remove the wooden block (1) or equivalent, and lower the rail into position.
    GC0157788Courtesy of CHRYSLER GROUP, LLC
  15. Loosely install the fastener (1) into the front of the rail (2).
    GC0157586Courtesy of CHRYSLER GROUP, LLC
  16. There are a total of seven rivets needed to install the partially removed rail. Locate two steel rivets and five aluminum rivets. The rivets (4) must be 4 mm (5/32 in.) wide (1) x 10 mm (3/8 in.) long (2) and with an 8 mm (5/16 in.) head (3). The rivet (6) installed total length must not exceed 5 mm (5/32 in.) (5).
    NOTE:

    Caution- Installing too long of rivets will not allow lifting arm assembly enough clearance to slide in the rail channel and will cause extensive damage to the folding top components.

    GC0157628Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Use paint sticks (1) or equivalent, placed between the contact points of the clamp (2) and the roof rail and the clamp and inner frame to prevent scaring of the surfaces.

  17. Using a welding clamp (2) with paint sticks (1) or equivalent, clamp the roof rail down only tight enough that there are no gaps between bottom of the roof rail and the top of frame. Over clamping will damage the roof rail.
  18. With the use of a rivet gun (3), install the front two steel rivets and working toward the rear of the vehicle the next four aluminum rivets.
    GC0157811Courtesy of CHRYSLER GROUP, LLC
  19. Position the rail spring (2) onto the roller (1) and position into the opening in the frame.
  20. Install the aluminum rivet.
    GC0157788Courtesy of CHRYSLER GROUP, LLC
  21. Tighten front fastener securing the rail to frame. Tighten fastener to 9 Nm (80 lbf-in)
  22. Remove the welding clamps and paint sticks, or equivalent.
  23. Grip the lifting arm and slide the lifting arm to the rear of the rail past where the rivets have been installed. There should be no stopping or binding.
  24. Slide the lifting arm to the front of the rail until completely seated against the front stop block.
  25. Repeat on the opposite side.
    NOTE:

    Failure to have both sides lifting arms in the full forward stop position when the motor and manual drive gear are installed will result with the cables being out of time/sync

    GC0157746Courtesy of CHRYSLER GROUP, LLC
  26. Grease the rubber grommets on the folding top motor.
  27. Position the folding top motor (2) and loosely install the three fasteners (2).
    GC0157605Courtesy of CHRYSLER GROUP, LLC
  28. Insert the 17 mm hex head manual drive gear (1) and listen for an audible "click" as it engages to the folding top motor.
  29. Position the manual drive gear plate and install the two fasteners (2).
  30. Tighten the fasteners (2) to 5 Nm (44 lbf-in)
    Fig 1: Folding Top Motor Fastener Tightening Sequence
    GC0157728Courtesy of CHRYSLER GROUP, LLC
  31. Tighten the folding top motor (1) fasteners, in the sequence shown, to 9 Nm (80 lbf-in).
    GC0153471Courtesy of CHRYSLER GROUP, LLC
  32. Connect the electrical connector to the motor (2) and the module (1).
  33. Connect the battery negative cable and make certain the motor and module are getting power.
  34. Disconnect and isolate the battery negative cable.
  35. Route and secure wiring harness to the rear shelf.
    GC0153472Courtesy of CHRYSLER GROUP, LLC
  36. Align and position the motor cover plate (2).
  37. Install the four rivets (1) securing the motor cover plate (2).
    GC0157849Courtesy of CHRYSLER GROUP, LLC
  38. Position the bottom rear shelf trim panel (2) to the rear shelf.
  39. Install the eight push pin fasteners (1) fully.
    GC0157614Courtesy of CHRYSLER GROUP, LLC
  40. At the rear of the vehicle, position the side curtain airbag (2).
  41. Install the two fasteners (1) and tighten the fasteners to 10 Nm (89 lbf-in).
    GC0157917Courtesy of CHRYSLER GROUP, LLC
  42. Position the washer/bushing (3) onto the wind deflector bracket (1) and repeat on the opposite side.
  43. Insert the hole on the wind deflector (2) onto the bracket (1).
  44. Opposite side, push inboard slightly, position the hole on the wind deflector (2) over the bracket (1) stud and release.
    GC0157745Courtesy of CHRYSLER GROUP, LLC
  45. Position the front rail cover (1) and clip to the rail.
    GC0157680Courtesy of CHRYSLER GROUP, LLC
  46. On the interior of the vehicle, install the push pin fastener (1) securing the front rail trim to the frame (2).
    GC0157805Courtesy of CHRYSLER GROUP, LLC
  47. If servicing the passenger side, install the rivets (2) securing the grab handle bracket (1).
  48. Insert the trim lace onto the frame edge.
    GC0153530Courtesy of CHRYSLER GROUP, LLC
  49. Position the headliner side rail (2) and secure the inner retainers with the use of hand pressure.
  50. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, route the trim lace and weatherstrip over the edges of the headliner side rail (2).
    GC0153211Courtesy of CHRYSLER GROUP, LLC
  51. If servicing the passenger side, install the grab handle (1). Refer to HANDLE, GRAB, INSTALLATION .
    GC0153216Courtesy of CHRYSLER GROUP, LLC
  52. Install the sun visor (2). Refer to VISOR, INSTALLATION .
    GC0153695Courtesy of CHRYSLER GROUP, LLC
  53. Position the coat hook (1) and turn a quarter turn to lock in place.
  54. Install the convertible roof cover. Refer to COVER, HEADER, INSTALLATION .
  55. Connect the negative battery cable.
  56. Verify the convertible roof cover is properly functioning.
  57. If the convertible roof cover is not functioning perform the Relearn procedure. Refer to FULL OPEN RETRACTABLE ROOF, POWER, STANDARD PROCEDURE .
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