Repair Procedure For Windshield Frame Adjustment

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This repair procedure is applicable when water is evident on the:

• Front floor (wet carpet)

Windshield Frame Inspection Criteria: 

The windshield frame adjustment should only be performed if the vehicle exhibits one of the following conditions:

• Gaps between the windshield frame and door exceeding 6.5 mm (.25 in.).
• Gaps between the windshield frame and top of cowl exceeding 6 mm (.23 in.) or less than 4 mm (.15 in.).
• Record measurements for reference.

1. Using a non-marring feeler gauge, measure the gap between the door and windshield frame and the gap between the windshield frame and top of cowl. Is the gap between the windshield frame and door larger than 6.5 mm (.25 in.)? Is the gap between the windshield frame and top of cowl larger than 6 mm (.23 in.) or less than 4 mm (.15 in.).
2. If yes, proceed with Windshield Frame Adjustment, otherwise continue further diagnosis.

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1 - Cross Bar Bolt

2 - B-Pillar Bolt

Windshield Frame Adjustment:

1. Remove the modular tops (Freedom Top) and hard top, Refer to REMOVABLE TOP, SOFT, REMOVAL .
   NOTE:

   It is important that the adjustments are made on one side of the windshield frame at a time. If both sides need to be adjusted, complete the whole procedure on one side, then repeat the procedure on the other side.

2. Loosen the side bars by pulling the cross bar and side bar covers off to expose the end side bar bolts.
3. Loosen but do not remove from the B-pillar.
4. Loosen but do not remove the bolt underneath the cross bar.

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5. The gray foam has access holes and should not be removed.
6. Loosen but do not remove the bolt on top of the side bar.
   NOTE:

   Do not remove the six gusset bolts. Loosening the bolts minimizes the risk of damaging the vehicles paint.

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7. Using a T40 Torx bit, loosen the six gusset bolts on one side of the windshield frame
8. Are the gaps between the door and windshield frame larger than 6.5 mm (.25 in.)?
   1. YES > Proceed to Repair Procedure A: Door to Windshield Frame Adjustment
   2. NO > The gaps between the windshield frame and cowl top are smaller than 4 mm (.15 in.). Proceed to Repair Procedure B: Windshield Frame to Cowl Panel Adjustment Gap less than 4 mm (.15 in).
      NOTE:

      Do not wrap the ratchet strap around the speaker bar. Failure to do so may damage speaker bar.

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Repair Procedure A: Door to Windshield Frame Adjustment

1. Loosen but do not remove the bolt on top of the side bar.

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2. Using a ratchet strap, secure it between the cross bar and the windshield footman loop.

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3. Using a non-marring feeler gauge, insert the 5 mm (.19 in.) gap gauge between the door and windshield frame. Tighten the ratchet strap pulling the windshield frame rearward until the gap is tight against the 5 mm (.19 in.) gauge.
   NOTE:

   An assistant is required to monitor the gap at the door to windshield frame as another individual is operating the ratchet strap.

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4. Tighten the bolt underneath the cross bar (1) to 19 N.m (14 ft. lbs.).
   NOTE:

   The B-pillar bolt is easy to strip out. Do not over tighten. Use a ratchet and socket to prevent stripping the bolt.

5. Tighten the B-pillar bolt (2) to 19 N.m (14 ft. lbs.).

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6. Tighten the bolt on top of the side bar (Fig. 8) to 19 N.m (14 ft. lbs.).
7. Replace the sport bar and side bar covers.

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8. Using a non-marring feeler gauge, check the gap between the windshield frame and top of cowl. Place the feeler gauge in the location shown on the left and right side of the windshield frame and measure the gaps
9. Are the gaps between 4 mm (.15 in.) and 6 mm (.24 in.)

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YES >

1. Tighten the bolt underneath the cross bar (1) to 19 N.m (14 ft. lbs.).
2. Tighten the B-pillar bolt (2) to 19 N.m (14 ft. lbs.).

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3. Tighten the bolt on top of the side bar to 19 N.m (14 ft. lbs.).

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NO > Proceed to the next step.

1. Is the gap smaller than 4 mm (.15 in.)?
   1. YES > Proceed to Repair Procedure B: Windshield Frame to Cowl Panel Adjustment Gap Less than 4 mm (.15 mm)
   2. NO > The gap is larger then 6 mm (.24 in.). Proceed to Repair Procedure C: Windshield Frame to Cowl Panel Adjustment Gap Greater than 6 mm (.24 in).

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Repair Procedure C: Windshield Frame to Cowl Panel Adjustment Gap Greater than 6mm (.24in)

1. Using a ratchet strap, fasten strap around the side bar.
   NOTE:

   Place a piece of cardboard or foam between the ratchet strap and any point it contacts the body or side step. Failure to do so may cause damage to paint.

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2. Hook the other end of the ratchet strap into the hole in the frame that is directly below front edge of the door
3. Tighten the ratchet strap pulling the windshield frame down until the gap is between 4 mm (.15 in.) and 6 mm (.24 in.).

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4. Using a T40 Torx bit, tighten the six gusset bolts on each side of the windshield frame in the pattern shown to 10 N.m (7.5 ft. lbs.).
5. Repeat Repair Procedure C for the opposite side of the windshield if needed.

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Repair Procedure B: Windshield Frame to Cowl top is less than 4 mm (.15 in.)

NOTE:

Perform the following steps if the gap between the windshield frame and cowl top is less than 4 mm (.15 in.).

1. Using a ratchet strap, fasten strap around the side bar on the opposite side of the gap (windshield frame) that's measuring smaller than 4 mm (.15 in.)

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NOTE:

Place a piece of cardboard or foam between the ratchet strap and any point it contacts the body or side step. Failure to do so may cause damage to paint.

2. Hook the other end of the ratchet strap into the hole in the frame that is directly below front edge of the door

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3. Tighten the ratchet strap pulling the windshield frame down until the gap is between 4 mm (.15 in.) and 6 mm (.24 in.).

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4. Using a T40 Torx bit, tighten the six gusset bolts on each side of the windshield frame in the pattern shown. Tighten bolts to 10 N.m (7.5 ft. lbs.)

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5. Repeat Repair Procedure B for the opposite side of windshield if needed.
6. Using a non-marring feeler gauge, re-check the gap between the door and windshield frame. Is the gap between 3.5 mm (.14 in.) and 6.5 mm (.25 in.)?
   1. YES > Proceed to the next step.
   2. NO > Repeat Repair Procedure A.

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7. Using a non-marring feeler gauge, re-check the left side and right side gaps between the windshield frame and top of cowl. Are gaps between 4 mm (.15 in.) and 6 mm (.24 in.)?
   1. YES > Proceed to the next step.
   2. NO > Repeat Repair Procedure B.
8. Install the hard top and modular tops (Freedom Top), Refer to REMOVABLE TOP, SOFT, INSTALLATION .