RALLY TOPS INSTALLATION INSTRUCTIONS

Hardtop Type: 1-Piece Removable Hardtop with Door Inserts
Truck Model: Jeep CJ5 Late Model (1976-1983) | Jeep CJ6 (1976-1981)

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:

  • 6 ea. 5/16 x 1 1/2 Hex Bolts
  • 6 ea. 5/16 x 18 Weld Nuts
  • 6 ea. 3/8 Flat Washers
  • 2 ea. Wood Spacers
  • 2 ea. Closed Catches
  • 4 ea. Sheet Metal Screws
  • 2 ea. 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 catches in the visor holes. Install top and bolts but don’t tighten yet.

3. Tape spacer on the rear of the door.

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

5. Adjust the door, by loosening the three hinge bolts on both hinges. IMPORTANT!! The bolt shown by the arrow is not to be tighten more than hand tight.

6. 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

Fig. #1

These hinges are not stock. Look at the placement of the hinge. See the stock hinge in fig. 2. It sits down more. Also notice that Fig. #1 hinge is set back into the door. Look at Fig 2, it’s not so far back.

Fig. #2

Fig. #3

Look at Fig #3 The top hinge in Fig#1 is stopping the lower hinge from going down, and the looks like it’s too far back. Should be like Fig. #4

Fig. #4

Fig. #5

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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