STANDARD PROCEDURE
HARD TOP REPAIR
NOTE: The hard top is manufactured from a sheet molded compound (SMC).
SMC is constructed using short fiberglass strands usually less than 5.08 cm (2 inches) long. Sheet stock of glass impregnated resin matting is placed into the mold and pressed under heat to flow material throughout the mold. Tooling is shear edge designed to mold to net (i.e. no trimming at periphery required).
SMC is repairable in accordance with established procedures described within this manual. (Refer to 23 - BODY - STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR)
Hard Top Locators
There are two hard top locator devices positioned approximately 50 mm (2 in.) from the most forward attachment holes for both two door and four door models. There is an additional locator on the passenger side at the upper B-post mount on four door hard top models.
If the black four way locator is missing, replace. In the event that the rivet stud is damaged or missing, drill out and replace.
HARD TOP REPAIR
If it has been determined that the hard top can be repaired. The following required materials and procedures are to be used.
1. Use a grinder to remove the paint and outline the damaged area. Use a grade 150 grit disc for paint removal.
2. Grind the outlined surface area again with a 240 grit disc to prevent coarse scratches from appearing in the final finish.
3. If cracks extend from the hole, it will be necessary to stop-drill the crack(s) with a 3-mm (1/8-in) diameter drill bit. This will prevent the crack from spreading and allow repair material to be effective.
4. Position a fiberglass mat or cloth on the repair surface area. Cut the mat 2.5 cm (1 in.) larger than repair area but smaller than the outline area. Make the outline area larger if required.
5. Clean the outlined area.
6. Place the fiberglass cloth on aluminum foil.
7. Pour the fiberglass resin into a clean container.
8. Mix the appropriate amount of hardener and resin. Follow the manufacturers instructions.
9. Apply the hardener/resin mixture to both sides of the fiberglass cloth.
10. Place the fiberglass cloth over the repair area. Next, place the aluminum foil over the cloth using a plastic spreader to smooth-out the cloth and resin. Use firm pressure to remove air bubbles and to smooth-out the cloth. Remove the aluminum foil.
11. Allow the resin to cure.
12. Smooth-out the surface area to the contour of the hard top with a 150-grit disc.
13. Apply plastic filler to complete the repair. Finish smoothing the surface area with 240-320 grit paper.
14. Repeat the previous steps on the inside area of the hard top.
15. Featheredge the repaired surface area.
16. Prime the repaired surface area with PPG® Epoxy Primer, or an equivalent product.
17. Apply surface primer to the surface area.
18. Prime the surface area for the color coat.
19. Apply color coat to the repaired surface area.
HARD TOP FRACTURE REPAIR
If it has been determined that the hard top can be repaired. The following required materials and procedures are to be used.
1. Use a grinder to remove the paint and outline the damaged area. Use a grade 150 grit disc for paint removal.
2. Grind the outlined surface area again with a 240 grit disc to prevent coarse scratches from appearing in the final finish.
3. If cracks extend from the damaged area, it will be necessary to stop drill the cracks with a 3-mm (1/8-in) diameter drill bit. This will prevent the crack and/or fracture from spreading and allow repair material to be effective.
4. Bevel the edges of the crack/fracture on both sides with a rotary file.
NOTE: The edges should be beveled on the inside and outside of the top to ensure sufficient surface area for good bonding.
5. Complete the repairs with fiberglass cloth and resin as described in the hard top hole repair procedure. (Refer to 23 - BODY/REMOVABLE TOP - STANDARD PROCEDURE)
HARD TOP SAG REPAIR
Inspect the roof/hard top assembly for the presence of sag, or if the customer complains of water accumulation on the roof. Perform the following procedure to repair.
1. Remove front freedom panels to gain access to the rear hard top assembly.
2. Remove the six bolts that attach the hard top to the body for a two door or eight bolts that hold down the four door.
3. Depress tab on rear wiper motor connector and pull downward to disengage.
4. Make two marks on the inside of the hard top 6 cm (2.5 in.) on both sides of the center roof rib, directly above the sport bar.
5. Move the hard top back about 10 cm (4 in.) to expose the inner rib section.
6. Clean the roof area with isopropyl alcohol.
7. Install the foam repair blocks by removing the protective backing tape from the adhesive side. The foam blocks must be centered above the sport bar pad.
8. Move the hard top assembly back into position.
9. Inspect the hard top seals for damage and replace, if necessary.
10. Inspect the windshield header seal and make sure it is clean, undamaged, and free of debris.
11. Carefully position the hard top assembly on the vehicle making sure that the latches are not pinched between the windshield frame and top.
CAUTION: Do not over tighten the top bolts. Over tightening can cause cracking of the hardtop assembly.
12. Loosely install the six bolts on a two door or eight bolts on a four door. Ensure that the top is centered on the vehicle and locators are in place in the body side holes and tighten the bolts to 18 N·m ( 13.5 ft. lbs.).
13. Connect the wire wiper motor harness connector.
14. Connect the rear washer fluid hose.
15. Install front freedom panels.