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Home >> Fiat >> 2017 >> 500 Pop, Standard Trans >> Repair and Diagnosis (Single Page) >> Body & Frame >> Windows >> Body - Interior & Exterior - 500 - Except Electric >> Full Open Retractable Roof, Power >> Frame, Folding Top >> Removal

Frame, Folding Top: Removal

GC0153450Courtesy of CHRYSLER GROUP, LLC
NOTE:

The windshield will need to be removed for this procedure. Windshield removal tools will also be used to remove the folding top frame. Do not attempt to remove the folding top frame without the appropriate tools.

  1. Open convertible top about 20 cm (8 in).
  2. Open the decklid.
  3. Disconnect and isolate the negative battery cable.
  4. Remove the decklid. Refer to DECKLID, CONVERTIBLE, REMOVAL .
    GC0153489Courtesy of CHRYSLER GROUP, LLC
  5. Lift the decklid weatherstrip (1), attached to the folding top five bow/bracket, to access the five bow bracket fasteners.
    NOTE:

    If the decklid weatherstrip's two-sided tape releases at all, peel the weatherstrip off completely.

    GC0153496Courtesy of CHRYSLER GROUP, LLC
  6. Remove the fasteners (1) from the five bow/bracket. Counting from the left to right-fasteners 1, 5, 7 and 11.
    GC0153497Courtesy of CHRYSLER GROUP, LLC
  7. Remove the five bow/bracket (1).
    GC0153470Courtesy of CHRYSLER GROUP, LLC
  8. From within the interior of the vehicle, remove the three fasteners securing the bracket (1) to the rear shelf (2).
  9. Remove the bracket (1).
  10. Remove the push pin retainers (3) from the rear shelf trim panel (2).
  11. Remove the rear shelf trim panel (2).
    GC0157579Courtesy of CHRYSLER GROUP, LLC
  12. With the use of trim tool (special tool #C-4829A, Remover, Trim) or equivalent, remove the push pin fasteners (1) from the rear lower headliner and c-pillar trim (3).
    GC0157598Courtesy of CHRYSLER GROUP, LLC
  13. Remove the push pin fastener under the lower package tray closeout panel (3).
  14. Position the C-pillar trim (1) and lower closeout panel (3) aside and release the headliner strap (2) hook and loop fastener.
    GC0157898Courtesy of CHRYSLER GROUP, LLC
  15. With the use of needle nose pliers or equivalent, remove the wire tie (2) securing the headliner sail panel strap (1) to the linkage. Grip the head of the zip tie and twist to remove
  16. Repeat on the opposite side.
    GC0157591Courtesy of CHRYSLER GROUP, LLC
  17. Release the lower headliner (2) hook and loop fastener from the rear window.
  18. Remove the sides of the headliner (1) from the rear window side retaining channels.
    GC0153780Courtesy of CHRYSLER GROUP, LLC
  19. Remove the upper headliner (1) from the rear window upper retaining channel.
    GC0153223Courtesy of CHRYSLER GROUP, LLC
  20. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the B-pillar trim panel (1) by releasing the retaining clip located at the bottom and upper rear areas. There is also a retaining clip that mates to the upper C-pillar trim. Repeat on the opposite side B-pillar trim panel.
  21. Pull downward on the B-pillar trim panel (1) and reposition.
  22. Repeat on the opposite side.
    GC0153493Courtesy of CHRYSLER GROUP, LLC
  23. Remove the fastener (2) from the upper area of the C-pillar trim panel.
  24. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the C-pillar trim panel retaining tabs/clips and reposition the C-pillar trim panel (1). Repeat on the opposite side.
    GC0157731Courtesy of CHRYSLER GROUP, LLC
  25. Unclip the CHMSL wiring harness connector (2) from the spoiler reinforcement.
  26. Disconnect the wiring connector (2).
  27. Release the wiring harness (1) routing clips from the spoiler reinforcement.
    GC0157701Courtesy of CHRYSLER GROUP, LLC
  28. Loosen the fasteners (1), securing the linkage (2) to the spoiler reinforcement (3), three to four turns.
  29. Repeat on the opposite side.
    GC0157592Courtesy of CHRYSLER GROUP, LLC
  30. Loosen the fasteners (1), securing the linkage (2) adjustment, three to four turns.
  31. Repeat on the opposite side.
    GC0157799Courtesy of CHRYSLER GROUP, LLC
  32. Along the bottom of the spoiler reinforcement (2), loosen the four fasteners (3) three to four turns. Do not remove the lower spoiler reinforcement fasteners (3). 
  33. Along the top of the spoiler reinforcement (2), remove the four spoiler fasteners (1).
    GC0153495Courtesy of CHRYSLER GROUP, LLC
  34. From outside the vehicle, remove the CHMSL harness grommet and pull the harness through the hole in the cover.
  35. Remove the spoiler assembly (1) from the cover.
    GC0153472Courtesy of CHRYSLER GROUP, LLC
  36. 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).
  37. If necessary, use a hammer and chisel to remove the heads of the rivets.
  38. Remove the motor cover plate
    GC0153471Courtesy of CHRYSLER GROUP, LLC
  39. Disconnect the electrical connector from the motor (2) and the module (1).
    GC0153498Courtesy of CHRYSLER GROUP, LLC
  40. On the exterior rear of the vehicle, lift the cover material up to expose the tension cable (2) and bracket (1).
  41. Remove the fastener securing the bracket (1) to the roof frame. Repeat on the opposite side.
    GC0157819Courtesy of CHRYSLER GROUP, LLC
  42. Separate the tension cable (2) from the bracket (1). Repeat on the opposite side.
    GC0157892Courtesy of CHRYSLER GROUP, LLC
  43. Remove the tension cable (1) through the opening (2) and out the end of the frame (3).
  44. Repeat on the opposite side
    GC0157844Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Use care not to loose C-clip (2) and washer (1).

  45. From inside the vehicle, remove the C-clip (2) and washer (1).
  46. Remove the pin and separate the backlight/glass bracket (3) from the linkage (4).
  47. Repeat on the opposite side.
    GC0157671Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Use care not to loose the three washers (3) located between the backlight/glass linkage (2) and the mounting bracket.

  48. Accessing from inside the vehicle, remove the pivot bolt (1) and nylon washer.
  49. Repeat on the opposite side.
    GC0157747Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Use care not to lose the center pin and push pin fastener.

  50. Use a small pick or equivalent, to push the center pin (3) from the push pin fastener (2).
  51. Using needle nose pliers or equivalent, remove the center pin (3) from the push pin fastener (2).
  52. Remove the headliner tether (1) from the linkage.
  53. Repeat on the opposite side.
    GC0157879Courtesy of CHRYSLER GROUP, LLC
  54. Inside the vehicle at rear C-pillar remove the zip ties (1) from harness along the bracket. Grab the head of the zip tie with a pair of needle nose pliers or equivalent, and twist.
  55. Disconnect defroster connector from the backlight.
  56. Remove zip ties from the harness.
  57. Route the harness out of the back glass channel.
  58. Repeat on the opposite side.
    GC0157933Courtesy of CHRYSLER GROUP, LLC
  59. Remove the fastener (1) from the four bow end cap (2).
  60. There will be a sleeve on the fastener, be careful not to drop or lose it.
  61. Repeat on the opposite side
    GC0157605Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Bottom rear shelf trim panel removed for clarity.

    NOTE:

    Caution- To prevent damage to the folding top motor, never use power tools to turn the folding top hex head drive gear (1).

  62. Under the rear shelf in the center is a 17 mm hex head (1), cycle the folding top open until the front roof bow folds over exposing the fasteners.
    GC0157846Courtesy of CHRYSLER GROUP, LLC
  63. Remove the front bow fasteners (2).
  64. Repeat on the opposite side.
    GC0157575Courtesy of CHRYSLER GROUP, LLC
  65. Manually cycle the cover to 3/4 closed position using the 17 mm hex head under the rear shelf.
  66. With the use of a drill equipped with a 4 mm (5/32) drill bit, drill out the rivet (3) securing the tension belt (1) to the lifting arm (2). Repeat on the opposite side.
  67. Use a vacuum to remove all drill shavings and debris
    GC0157653Courtesy of CHRYSLER GROUP, LLC
  68. Separate the cover from the second bow retainer (1) by pushing the roof bow rearward, releasing the bow end cap from the lift up spring.
    GC0157866Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Do not loose O-ring gasket (1) on the linkage arm stud.

  69. Push the linkage arm (2) inboard to disconnect from the folding top slide bracket (3).
  70. Repeat on the opposite side.
  71. Fold the rear portion of the roof forward onto itself
    GC0153515Courtesy of CHRYSLER GROUP, LLC
  72. Detach the seal at the bottom of the rear rail cover (1).
  73. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the rear track cover (1) by prying up the outboard edge of the cover and rolling the track cover inward. Repeat on the opposite side.
    GC0157648Courtesy of CHRYSLER GROUP, LLC
  74. Remove the fastener (2) securing the rear stop block (1).
  75. Slide the rear stop block (1) out of the rear of the rail.Do not misplace the square nut insert on the back of the stop block, if applicable. 
  76. Repeat on the opposite side.
    GC0157615Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    To prevent damage to the stow slider block screw, use an appropriate flat bladed tool.

    NOTE:

    Use a flat bladed tool (2) that fits properly into the thickness of the center slot of the screw head on the folding top slide bracket (1). Due to the small size of the screw, it will be tempting to use a small flat bladed tool. A smaller flat bladed tool may not have enough thickness on the blade to fill the center slot in the screw head properly. Using too small of a flat bladed tool may strip the head of the screw.

  77. Disengage the hook on the right folding top slide bracket (1) by turning the front screw clockwise a half turn, while gently moving the stow slider block back and forth.
  78. Disengage the hook on the top left folding top slide bracket (1) by turning the front screw counter clockwise a half turn, while gently moving the stow slider block back and forth.
  79. Remove the folding top slide brackets from the rear of the rails.
    GC0157874Courtesy of CHRYSLER GROUP, LLC
  80. With the help of an assistant on the opposite side, simultaneously slide the cover rearward to remove the roof bow slider (1) blocks from the rail (2).
  81. Remove the folding top cover and place on a clean dry surface.
    GC0153755Courtesy of CHRYSLER GROUP, LLC
  82. Using a small pry tool, remove the cover (2) located on the rear of the mirror.
  83. Remove the harness cover (1).
    GC0153756Courtesy of CHRYSLER GROUP, LLC
  84. Disconnect the harness (1) from the rear view mirror (2).
  85. Disengage the tab that secures the rear view mirror (2) to the support bracket/button on the inside of the windshield glass.
  86. Slide the rear view mirror upward to remove.
    GC0153216Courtesy of CHRYSLER GROUP, LLC
  87. Remove the dome lamp and power top switch. Refer to SWITCH, POWER TOP, FULL OPEN RETRACTABLE ROOF, REMOVAL .
  88. Remove the visor (2) and visor support.
    GC0153529Courtesy of CHRYSLER GROUP, LLC
  89. Remove the rivet (2) located in the dome lamp cavity securing the front header cover (1) to the roof header.
  90. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the retaining clips located under the visor support cavities and remove the front header cover (1).
    GC0153695Courtesy of CHRYSLER GROUP, LLC
  91. Remove the front header cover. Refer to COVER, HEADER, REMOVAL .
  92. Remove the grab handle, Refer to HANDLE, GRAB, REMOVAL .
  93. Twist the coat hook (1) counter clockwise to the "9 o'clock" position and pull straight out to remove.
    GC0153530Courtesy of CHRYSLER GROUP, LLC
  94. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, pry the headliner side rail (2) away and reposition.
  95. Remove the fastener (1) securing the tether to the airbag.
  96. Remove the headliner side rail (2).
    GC0153174Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Airbags must be stored in a clean, dry environment; away from sources of extreme heat, sparks and high electrical energy. Always place or store any airbag on a surface with its trim cover or airbag cushion side facing up, to minimize movement in case of an accidental deployment.

  97. Remove the A-pillar trim panel. Refer to PANEL, A-PILLAR TRIM, REMOVAL .
  98. Disconnect the body wire harness connector (2) for the Side Curtain Airbag Inflatable Curtain (SABIC) (5) from the connector receptacle at the back of the inflator between the upper inner B-pillar (1) and the upper inner C-pillar.
  99. Remove the screw (4) that secures the rear locating hook of the SABIC to the weld nut in the upper inner C-pillar.
  100. Remove the nut that secures the SABIC rear tether anchor to the weld stud on the upper inner C-pillar.
  101. Disengage the rear tether anchor from the upper inner C-pillar.
    GC0153178Courtesy of CHRYSLER GROUP, LLC
  102. Remove the screw (1) that secures the SABIC (2) front tether to the lower inner A-pillar (3).
  103. Remove the remaining screws (1) that secure the SABIC (2) and the inflator bracket to the inner roof side rail.
  104. Disengage the push-in plastic fastener that secures the SABIC mounting tab to the inner A-pillar.
  105. Disengage the remaining locating hooks of the SABIC from the inner roof side rail.
  106. Disengage the remaining hook and T-tab that secure the SABIC inflator from the slots in the inner roof side rail.
  107. Remove the SABIC from the vehicle as a unit.
    GC0080800Courtesy of CHRYSLER GROUP, LLC
  108. If equipped, disconnect the rear view mirror harness.
  109. Remove the cowl grille Refer to COVER, COWL PANEL, REMOVAL .
    CAUTION:

    Be careful not to damage painted surfaces when removing moldings or cutting urethane around the windshield.

  110. Remove molding from the top of the windshield.
  111. Using an assistant and a wire-type windshield cut-out tool (1, 3 and 4), cut and separate the urethane adhesive (2) securing the windshield to the windshield fence.
    GC0153754Courtesy of CHRYSLER GROUP, LLC
  112. Using appropriate tools, carefully remove the windshield (1) from the vehicle.
    GC0153752Courtesy of CHRYSLER GROUP, LLC
  113. Remove the roof weatherstrip (1).
    GC0153743Courtesy of CHRYSLER GROUP, LLC
  114. Accessing from the vehicle interior, remove the front fastener (1) securing the frame to the vehicle. Repeat on the opposite side.
    GC0153744Courtesy of CHRYSLER GROUP, LLC
  115. Accessing from the vehicle interior, remove the fastener (1) located in the upper C-pillar area securing the frame to the vehicle. Repeat on the opposite side.
    GC0153745Courtesy of CHRYSLER GROUP, LLC
  116. Accessing from the vehicle interior, remove the fastener (1) located in the lower C-pillar area just above the package tray, that secures the frame to the vehicle. Repeat on the opposite side.
    GC0153749Courtesy of CHRYSLER GROUP, LLC
  117. Remove the two fasteners (1) located under the package tray securing the package tray/frame to the vehicle.
    GC0153784Courtesy of CHRYSLER GROUP, LLC
  118. Remove the three fasteners (1) securing the lower rear portion of the frame to the body.
    GC0153731Courtesy of CHRYSLER GROUP, LLC
  119. To aid in protection of the to body side, make a shield out of bent scrap stock and place at front of aperture (3) where front edge of folding top frame (2) ends.
    GC0153746Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Use appropriate cautionary measures to avoid damaging the painted surfaces of the vehicle.

  120. Using windshield pull knife, start at one side of the front header section of the frame (1) and work across to cut away urethane.
    GC0153747Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Use appropriate cautionary measures to avoid damaging the painted surfaces of the vehicle.

  121. Using windshield pull knife, start at the front section of the frame (1) and work rearward to cut away urethane. Repeat this process on the opposite side
    GC0153748Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Use appropriate cautionary measures to avoid damaging the painted surfaces of the vehicle.

  122. Using windshield removal tool such as an extractor or equivalent, start at the rear section of the frame and work across to remove urethane.
  123. If necessary, have an assistant lift up the front of the frame. Access from the vehicle interior just under the package tray to remove any additional urethane.
  124. With the help of two (or possibly three) assistants, lift the frame at the front and rear corners and remove the frame from the vehicle.
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