RALLY TOPS INSTALLATION INSTRUCTIONS

Hardtop Type: 2-Piece Removable Hardtop with Half-Door Insert
Truck Model: Jeep Wrangler TJ (1997-2006)

General Safety Information:

Instructions – Safety

Your Rally Tops Hardtop will come with all the necessary parts to complete your installation. To safely lift and install this hardtop, you will need the assistance of at least one other person. The following instructions are examples of the installation. Please follow the instructions that are included with your Rally Top.

REMEMBER: 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.

Instructions – Warning

WARNING: The top on this vehicle is designed only for additional protection against the elements. Do not rely on the top to contain occupants within the vehicle or to protect against intrusion of foreign objects, nor injury during an accident. Make sure all brackets and screws are tight. Periodically check for tightness and retighten when necessary. Wear seat belts at all times.

Parts Provided (Hardtop):

  • 6 each – Bolt 5/16 x 18 x 1 1/4
  • 6 each – Nut 5/16 x 18
  • 9 each – Washer 5/16
  • 3 each – Wing Nut 5/16
  • 3 each – Side Brackets
  • 1 each – Center Bracket
  • 1 each – Instruction Sheet

Parts Provided (Half-Door):

  • 2 each — 3/8″ x 4.5″ Button head bolts – uses 7/32 allen wrench
  • 4 each — 3/8″ x 5.0″ Button head bolts – uses 7/32 allen wrench
  • 6 each — 3/8″ Nylon washers
  • 6 each — 3/8″ Steel washers
  • 6 each — Door inserts
  • 1 each — Left upper half door
  • 1 each — Right upper half door
  • 1 each — Instruction sheet

Instructions:

Follow the instructions and perform the steps in the sequence given. Shortcuts to the directions may result in an unsatisfactory installation.

A. HARDTOP INSTALLATION:

1. Unzip side windows and remove.

2. Unzip rear window and remove.

3. Pull back bar to disengage and remove.

4. Pull down on corners and remove.

5. Pry open side connections with screwdriver.

6. Remove side connections to door frame.

7. Disengage soft top from windshield.

8. Pull back soft top.

9. Remove bolt from soft top frame.

10. Pry off soft top frame from roll bar.

11. Remove soft top.

12. Unscrew door pins & remove frames.

13. Remove rear bar holders.

14. See pre-installation instruction sheet.

15. Do not remove end seal.

16. Using 2 or more people put the rear section on, followed by the front section.

17. Sit in the front seat. Make sure the windshield stop is not hung up on the ! molding. It should look like this.

18. Make sure the front section is centered on the windshield. Push it from the side to center it.

19. Install the flange bolts on the side rails and tighten lightly.

20. Install the side clamps, using the washers and wing nuts. The clamp should be installed with the 90 degree angle facing the back and inward. Do not tighten.

21. Using a side clamp bracket and the center bracket. Install the center support, using the washer and wing nut.

22. Try the doors to make sure you have proper clearance. Too tight and the door seal will stick, too loose and the door will leak wind. Adjust by moving the rear top back.

23. Engage the front cam locks, adjust to medium tension. Look at the windshield in the front, the top should be down

24. Tighten the rear flange bolts. Tight the 3 front section wing nuts. Very slowly shut the rear door, make sure it is not binding. Now swing the gate closed.

You’re Done! Enjoy!

B. HALF-DOOR INSTALLATION:

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.

2. Easily 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)

3. Install the new door inserts back into the lower door holes. There is a tab on one side of the insert, it can only fit into the hole in one direction. If the inserts are installed properly, the top plastic flange will rest against the top portion of the door.

4. Place the metal washer first and then the plastic washer onto the bolts. Place the upper half door onto the lower half door. Insert the bolts, 4.5″ bolt in the front and the 5.0″ bolts in the back two holes.

As you tighten the bolts, from the top of the insert, pull in, until they are snug. DO NOT OVER TIGHTEN.

Need more help?

Installing your Rally Top sport truck hardtop is a simple process, but we are always ready to lend expert advice.

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