RALLY TOPS INSTALLATION INSTRUCTIONS

Hardtop Type: 1-Piece Removable Hardtop with Door Inserts
Truck Model: Jeep CJ5 Early Model (1954-1971) | Jeep CJ5 Intermediate Model (1972-1975) | Jeep CJ6 (1955-1975)

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:

  • 4 ea. 5/16•18 x1 1/2” Hex Bolts (large)
  • 12 ea. 5/16•18 Weld Nuts (large)
  • 4 ea. 3/8” Flat Washers
  • 2 ea. 1/4 • 20 x 1 1/4” Hex Bolts (small)
  • 2 ea. M6 x 25 Flat Black Washer (cut)
  • 2 ea. 1/4•20 x 7/16” Weld Nuts (small)
  • 2 ea. Wood Spacers
  • 2 ea. Closed Catches
  • 6 ea. 8 x 3/4 Mod Truss Sheet Metal Screws
  • 2 ea. Lower Door Hinge Set Two each in a package
  • 2 ea. Windshield End Plates
  • 2 ea. Door Keys

Tools/Materials Required:

  • #2 Phillips screwdriver
  • 11 mm wrench
  • M6 Allen wrench
  • 1 tube of silicone sealant

Instructions:

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

A. PRE-INSTALLATION:

1. Place your tape on top ledge of the windshield.

2. Extent the tape to the rear of the body.

3. Where the tape hits the body , it should read the value in the chart below. Measure both sides. If it does, put the top on. If not, go to step 4.

  • CJ 5 (1972-1975) — 70 3/4”
  • CJ 5 (1976-1983) — 67 1/4 “
  • CJ 7 & YJ — 75 1/8”
  • CJ 8 — 97 11/16”
  • TJ — 75 1/8”
  • Unlimited — 89 7/16”

4a. CJ 5 Loosen the bolts and wing nut. Adjust windshield and tighten.

4b. CJ7 – CJ 8 – YJ Loosen bolts using a T40 torx wrench. Go to step 5.

4c. TJ & Unlimited Using a T40 Torx wrench, loosen the bolt above the doors hinge. Go to step 5.

5. Using a T50 tamper resistant Torx wrench or vise-grips, loosen this bolt. On the CJ 7 & YJ’s it’s on the top of the roll bar. On the TJ & Unlimited it’s on the side of the roll bar. This will be a 2 person job. One checks the measurement, the other person tightens the bolt. Remember 75 1/8” on both sides. (Unlimited 89 7/16”). Once this is accomplished, tighten up the bolt you loosened in step 4. Now you can put your top on. If the windshield is properly adjusted, the space between the windshield and the door should be the same on both sides.

B. INSTALLATION

1. Preform the pre-installation instructions.

2. Install the top on vehicle. Use the large bolts in the front holes. Try and use the large bolts in the rear holes. If they don’t work use the small bolts. Do not tighten bolts all the way

3. With the top in the proper position, drill a small pilot hole directly below the front camlok. Install catch using supplied screw.

4. Install new door end plates on the side on the windshield. Using the double sided tape and the existing screws.

3. Tape spacer on the rear of the door.

4. Tape spacer to the rear of the door opening.

7. Put masking tape on the body in the area under the new hinges.

8. Using 2 people, mount the door in the opening. Make sure you have an even space around the door. Use the spacers as a guide. Now slide the lower hinge onto the door, one at a time and mark the center of the 2 holes. Remove the door and drill the four 7/16” holes in the body. Remove the masking tape from around the holes and install the hinges using the bolts from the package and the weld nuts. Now install the doors.

5. Adjust the door, by loosening the three hinge bolts on both hinges (Look at examples of mis-aligned doors at the bottom of the page). IMPORTANT!! The bolt shown by the arrow is not to be tighten more than hand tight.

10. Check the door lock for proper operation. Loosen the two screws to adjust the catch. When your satisfied, install the remaining two screws and tighten.

7. You might have to go back and forth on the door and top adjustments, before you get it.

8. Tighten the rail bolts and the cam locks. Please send us a picture. We are proud of our work.

C. HINGE ALIGNMENT EXAMPLES

The door on the left is properly fitted. Notice the notch in the door matches the windshield to body contour. Now look at the door on the right, see the door notch is too high. The door needs to come down, so that is matches the windshield to body contour.

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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