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Jeep Upper Half Door Installation

 

Jeep YJ 1987-1996 and Jeep TJ 1997-2006
 
Warning: This product is designed only to enhance the appearance of the vehicle and to protect against some undesirable weather conditions. It is not designed to hold occupants inside the vehicle, or to protect against foreign objects, or as protection in the event of an accident. Occupants should always wear seat belts at all times.
 
Instructions
1. Remove the soft upper half doors. Remove the factory installed Jeep door inserts by using a large flat-bladed screw driver and gently prying them up. (See image to the right)
   
2. Once started, the door inserts can then easily be removed by hand. There should be three (3) per side. (Please note the positioning of the Jeep Door Inserts before removal. The flange of the inserts must be rotated correctly in order for the inserts to sit flush with the door when reinstalled). (See image to the right)
   
3. Install the Insert Nut into the bottom of the Jeep Door Insert.
  1. Place Insert Nut on a firm flat surface.
  2. Line up the Jeep Door Insert over the Insert Nut.
  3. While holding the Jeep Door Insert in place use your other hand to force the Insert Nut into the Jeep Door Insert. This can be accom plished by striking the Jeep Door Insert with the palm of your hand with just enough force for the Insert Nut to slide over the metal claws and into the holes at the bottom of the Jeep Door Inserts.
   
4. Because of the close manufacturing tolerances of the front lower door insert hole, it may be necessary to bend the metal claws inward slightly using a bench vise or pliers before reinstalling the front Door Insert.
   
5. Replace the Door Inserts (with insert nuts attached) back into the lower half doors. Be careful not to damage the Door Inserts when reinstalling them. If the Inserts are installed properly, the top plastic flange will be resting flat against the top portion of the door.
   
6. Place the bolts with the composite washers (the rubber part of the washer down), into the upper half doors. The 4” bolts should be put into the front hole of each door.  
   
7. With all 3 bolts in their proper holes, place the fiberglass upper half door over the metal lower half door, aligning the bolts into the three holes in the top of the lower metal half door.  
   
8. Tighten the bolts into the insert nuts until snug. DO NOT OVER TIGHTEN.  
   
9. Complete a door alignment check. Slowly close the door to make sure that
it fits correctly. The door should close without the upper half door hitting
the hardtop and the door gasket should fit firmly in place. If it does not,
you should try the following:
  1. Make sure the upper half door is installed correctly to the lower metal half door.
  2. Check the website for hardtop alignment instructions. See http://www.rallytops.com/installation/jeep-preinstallation-instructions.html
  3. Check lower door alignment to make sure the lower doors are fitted correctly.
   
It is the owner’s responsibility to insure proper installation and perform monthly maintenance checks of fasteners. Doing so will assure safe operation and long life of your upper hard doors.