Bestop Sunrider User manual

Installation Instructions
INSTALLATION TIME SKILL LEVEL
3 Hours 3 - Moderately Difficult
TOOLS
Vehicle Application
•Jeep TJ
2003 – 2006
Part Number: 51719
Sunrider®
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#2 T30
US Patents 5979968, 5765903

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 2
Tailgate Retainer Mount, Left,
Qty - 1, Part Number 311.85
Tailgate Retainer Mount, Right,
Qty - 1, Part Number 311.86
Rear Bow, Qty - 1,
Part Number 316.58
Door Surround - Left, Qty - 1,
Part Number 316.63 Door Surround - Right, Qty - 1,
Part Number 316.62
Center Bow, Qty - 1, Part
Number 316.55
Windshield Header Assembly,
Qty - 1, Part Number 386.44
Tailgate Bar, Qty - 1,
Part Number 288.75
Side Bow - Right,
Qty - 1, Part
Number 316.48
Side Bow - Left,
Qty - 1, Part
Number 316.49
Outboard Rear Bow
Bracket - Right, Qty - 1,
Part Number 315.70
Inboard Rear Bow
Bracket - Right, Qty - 1,
Part Number 315.68
Inboard Rear Bow
Bracket - Left, Qty - 1,
Part Number 315.69
Outboard Rear Bow
Bracket - Left, Qty - 1,
Part Number 315.71
Parts List and Hardware Identification
Top Fabric Qty - 1
Quarter Window, Right Qty - 1
Quarter Window, Left Qty - 1
Rear Window Qty - 1
Windshield Header Trim Qty - 1
Locktite Qty - 1

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 3
#8 x 1/2" Pan Head Washer
Screw - Black, Qty - 4, Part
Number 200.48
5/16-18 x 1" Phillips Head Bolt,
Qty - 2, Part Number 236.20
5/16-18 Tapping Plate, Qty - 2,
Part Number 200.50
5/16" Black Washer,
Qty - 2, Part
Number 233.04
10-32 Lock Nut, Qty - 10,
Part Number 316.94
Rear Bow Bracket
Bumpers, Qty - 2,
Part Number 315.74
Rear Door Surround
Bracket - Right, Qty - 1,
Part Number 315.66
Rear Door Surround
Bracket - Left, Qty - 1,
Part Number 315.67
Front Door Surround
Brackets, Qty - 2,
Part Number 315.75
Sun Roof Links, Qty - 2,
Part Number 315.59
Knobs, Qty - 4, Part
Number 316.85
Sleeves, Qty - 2,
Part Number 315.58
Main Pivot Bracket - Right,
Qty - 1, Part Number 386.47
Main Pivot Bracket - Left,
Qty - 1, Part Number 386.48
1/8" Allen Wrench, Qty - 1,
Part Number 276.68
10-32 Shoulder Bolt, Qty - 6,
Part Number 316.54
10-32 x 1.25 Screw, Qty - 2,
Part Number 316.93
10-32 x 1/2" Screw, Qty - 2,
Part Number 316.82
Bushing, Qty - 2,
Part Number 235.91
#10 Phillips Head Self Tapping Screw,
Qty - 8, Part Number 319.99
M6 Hex Screw, Qty - 4,
Part Number 322.41
#10 Star Washer, Qty - 8,
Part Number 317.58
J-Clip Strap, Qty - 1,
Part Number 321.71

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 4
When reinstalling Speak-
er Pods, be careful not to
pinch the wires between
the edge of the Speaker Pod and the Sport Bar.
If your vehicle has a cover over the Center Sport
Bar, unzip the cover to access the bar.
Locate the Main Pivot Brackets in the parts kit.
Orient the brackets with the tab toward the top and
the rear of the vehicle. Align the holes in the bracket
with the holes in the bar and install the bracket us-
ing two M6 Hex Screws for each bracket.
Stretch the cover around the bar and slip the open-
ings in the cover over the tabs on the Main Pivot
Brackets. Zip the cover closed.
Sport Bar
Cover Main Pivot Bracket
M6 Hex
Screws
These M6 screws have special threads
which will self-tap into non-threaded
holes as well as provide a tight, vibration resistant
attachment in pre-threaded holes.
Install Main Pivot Brackets
Locate the parts of the Right and Left Rear Bow
Brackets in the parts kit. Each bracket has two
pieces which are stamped R (right) and L (left).
Match rights and lefts.
If your vehicle has a cover over the Rear Sport Bar
Legs, unzip the cover to access the bar.
You will have to slip the parts of the Rear Bow
Brackets between the impact foam and the rear
sport bars. To do this, slip the Inboard half of the
bracket under the foam and around the sport bar
until the slot in the rear of the bracket is exposed
on the opposite side. Hook the tab on the Outboard
half into the slot and rotate the two pieces into posi-
tion so that the tab on the bracket hooks into the
rear opening of the seat belt cylinder.
If you have a Sport Bar Cover, wrap the cover
around the bar and mark the location of the tabs on
the Rear Bow Brackets. Cut openings in the cover
for the tabs. Slip the new openings in the cover
over the metal tabs and zip the cover closed.
Locate the Rear Bow Bracket Bumpers in the parts
kit and slip them over the two top tabs in each
bracket. Install a 10-32 x 1/2" Screw and a 10-32
Lock Nut through the bumpers and bracket.
Install Rear Bow Brackets
Use pliers to squeeze the top tabs, if
necessary, to align the holes and im-
prove ease of installation of the Bracket Bumpers.
Rear Sport Bar
Rear Seat Belt
Cylinder Opening
Rear Bow
Bracket
10-32 x 1/2"
Screw Outside
Driver's Side Shown
Rear Bow
Bracket Bumper
10-32 Lock
Nut
Hook tab on Outboard
half into slot in Inboard
half
Outboard
Inboard
Impact Foam
Impact Foam
Slide Bracket under
Impact Foam

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 5
Locate the Left and Right Door Surrounds, the Front
Door Surround Brackets and the Left and Right Rear
Door Surround Brackets in the parts kit.
Place the holes in the Front Door Surround Brackets
over the front pair of holes on each Door Surround,
farthest from the bend. Orient the brackets with the
long tab toward the inside and with the threaded
rivet up. Install the brackets using two #10 Phillips
Head Self Tapping Screws and two #10 Star Wash-
ers for each bracket.
Orient the Rear Door Surround Brackets with the
Spring Plunger toward the inside and to the front of
the Door Surround. Align the holes in the brackets
with the second pair of holes in the Door Surrounds
and install them using two #10 Phillips Head Self
Tapping Screws, two #10 Star Washers and Loctite
for each bracket.
Front
Toward
Front
Door Surround
Rear Door
Surround Bracket
Spring Plunger to inside
and front of Door Surround
#10 Phillips Head Self Tapping Screws (apply
Loctite to the threads) and #10 Star Washers
#10 Phillips Head Self Tapping
Screws (apply Loctite to the
threads) and #10 Star Washers
Front Door
Surround Bracket
Door Surround Door Surround -
Driver’s Side Shown
Assemble Door Surrounds
and Front and Rear Door
Surround Brackets
Horizontal Support
Bar
Knob
Rear Door Surround
Bracket from Top Door Surround
Rear Door
Surround Bracket
Orient the Left and Right Door Surround Assem-
blies on the vehicle with the brackets toward the
inside. Insert the nipples in the brackets into the
holes in the bottom of the Horizontal Support Bar.
Thread a Knob from the parts kit through the top
of the Horizontal Support Bar and into each of
the Door Surround Brackets. Close the door to
check the seal and adjust the Front Door Surround
Bracket if necessary for a good seal.
Knob
Detail of
Knobs
Door Surround Bracket -
Front or Rear
Horizontal
Support Bar
Thread Knob
into Bracket
Front Door Surround
Bracket
Horizontal
Support Bar
Door Surround
Front Door Surround
Bracket from Bottom
Install Door Surround
Assemblies

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 6
Driver's Side
Shown
Door
Surround
5/16" Washer
5/16-18 Tapping
Plate - under ledge
5/16-18 x 1 Phillips
Head Bolt
Secure the bottom of the Door Surround to the ve-
hicle using a 5/16-18 x 1 Phillips Head Bolt, a 5/16"
Washer and a 5/16-18 Tapping Plate. Place the
Tapping Plate under the ledge, aligning the hole in
the plate with the hole in the vehicle and install the
screw and washer from the top. Test the door seal
again and adjust the bottom of the Door Surround if
necessary for a good seal.
Install Door Surround
Assemblies
Rear Sport
Bar
Rear Bow
Rear Bow
Bracket
10-32 x 1-1/4"
Screw
10-32 Lock Nut
Locate the Rear Bow in the parts kit. Ori-
ent the bow on the vehicle with the snaps
toward the inside and up. Place the ends
of the bow between the tabs in the Rear
Bow Brackets, aligning the holes in the
bow with the holes in the brackets. Install
a 10-32 x 1-1/4" Screw from the outside
and a 10-32 Lock Nut on the inside.
Install Rear Bow
Locate the Left and Right Side Bows in the parts
kit. Orient them with the longer leg toward the front
and with the round recesses in the knuckles toward
the outside of the vehicle. Place the slot in the rear
knuckle over the tab on the Main Pivot Bracket. In-
stall a 10-32 Shoulder Bolt into the round recess on
the outside and a 10-32 Lock Nut in the hex recess
on the inside for each bow.
10-32 Shoulder
Bolt
10-32
Lock Nut
Front
Center Sport
Bar
Side Bow
Install Side Bows
Main Pivot
Bracket

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 7
Make sure the Sun Roof Link is rotated
90° to the knuckles. This is the only
position that will allow installation.
Windshield Header
Assembly
Sleeve - Slide
over rod
Locate the Windshield Header Assembly, the
Sleeves and the Sun Roof Links in the parts
kit. Slide the open end of the Sleeves (align the
grooves in the Sleeve with the metal clips) over
each rod on the header assembly and push it up
far enough to access the knuckle on the end of
each rod.
Place a Sun Roof Link, with the flat side toward
the rear, into the slot in the knuckle on each rod of
the assembly. Install a 10-32 Shoulder Bolt into the
round recess on the knuckle and a 10-32 Lock Nut
in the (hex) recess.
10-32 Lock Nut Sun Roof Link
10-32 Shoulder
Bolt
Assemble Windshield
Header Linkage
Windshield Header
Assembly
Side Bow
Orient the Windshield Header Assembly on the
vehicle and lay it along the top edge of the wind-
shield. Rotate the header assembly 180° back about
the pivot and lay the assembly down onto the side
bows. Slip the Sun Roof Links, attached to the as-
sembly in Step 8, into the slots in the knuckles on
the front ends of the Side Bows. Attach the links to
the Side Bows by inserting a 10-32 Shoulder Bolt
into the round recess from the outside and placing a
10-32 Lock Nut into the hex recess on the inside of
both Side Bows. Close the header by rotating it back
about the pivot.
10-32 Lock Nut
10-32 Shoulder
Bolt
Sleeve
Sun Roof
Link
Install Windshield Header
Make sure the Sun Roof Link is rotated
90° to the knuckles. This is the only
position that will allow installation.

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 8
Locate the Center Bow and the Plastic Bushings in
the parts kit.
Orient the bow with the rods toward the front of the
vehicle and place it with the feet resting on the Side
Bow.
Remove the inside 8-32 x 1/2" Screw and #8 Star
Washer from the Side Bow. Place a Bushing over
the end of the Standoff between the Side Bow
and the Center Bow Rod. Apply Loctite 271 to
the threads of the 8-32 x 1/2" Screw. Reinsert the
Screw and the #8 Star Washer into the Standoff.
Remove the outer 8-32 x 1/2" Screw and Star
Washer from the Side Bow, apply Loctite 271 to
the threads and reinsert the Screw and Washer.
Securely tighten the Screws. Do this on both sides
of the vehicle.
Center Bow
Rod Windshield Header
Assembly
Side Bow
Sleeve
Sun Roof
Link View from
Inside Vehicle
Detail of Center Bow Rod
to Side Bow Assembly
Side
Bow Center Bow Rod
Bushing
8-32 Standoff
#8 Star Washer
Inside
#8 Star Washer
Outside
8-32 x 1/2" Screw
(apply Loctite to
the threads)
8-32 x 1/2" Screw
(apply Loctite to
the threads)
Install Center Bow Locate the left and right Tailgate Retainer Mounts.
Place the mounts flush with the edge of the tailgate
opening. Install the Tailgate Retainer Mounts with
two #8 x 1/2" Pan Head Washer Screws for each
mount.
If your vehicle does not have holes at this loca-
tion, align the Tailgate Retainer Mounts flush with
the edge of the tailgate opening. Then mark the
locations of the holes in the mounts, center punch
and drill a 1/8" hole at the marked locations. Install
the mounts with two #8 x 1/2" Pan Head Washer
Screws for each mount.
Tailgate Retainer
Mount (Left)
Tailgate
Opening
#8 x 1/2" Pan Head
Washer Screws
Place Tailgate
Mount flush with
edge of opening
Install Tailgate Retainer Mounts

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 9
Drape the fabric, inside out, over the tailgate, align-
ing the snap flaps inside the rear opening with the
snaps on the Rear Bow. The center flaps wrap un-
der to snap to the bow and the outside flaps wrap
over to snap to the bow.
Drape fabric over
rear of vehicle
Outside
flaps wrap
over to
snap
Inside flaps wrap
under to snap
Snap Top Fabric to Rear Bow
Pull the deck up over the center bow to the
Windshield Header Assembly. Open the
Sun Roof and stand inside the vehicle to
access the front of the assembly. Wrap the
front edge of the Top Fabric around the front
edge of the Windshield Header Assembly.
Make sure that the fabric is centered on
the header. Press the plastic retainer along
the front of the top into the channel on the
header until it snaps into the channel.
Make sure the plastic retainers is
snapped firmly into the Header
channel. The Sun Roof feature will not
work properly if the retainer is not securely
installed.
Wrap Fabric around
Windshield Header and
snap plastic retainer into
channel in header
Secure Top Fabric to Windshield Header
Belt
Rail
Plastic
Strip
Fabric
Insert the plastic strips at the rear corners of the top
into the corners of the belt rails that are built into the
top edge of the vehicle.
Secure Top Fabric to Belt Rail

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 10
To secure the Side Bows to the Rear Door Surround
Brackets, place each Side Bow into the bracket and
push on the rear of the Side Bow, to snap it into
place. The Spring Plunger on the bracket must snap
into the hole in the Side Bow to fasten it securely.
Door Surround
Rear Door Surround
Bracket
Side Bow -
Place in bracket
Press on Side Bow from
the rear to snap into Rear
Door Surround Bracket
Secure Side Bows to Rear
Door Surround Brackets
Rotate the Windshield Header Assembly to
the windshield and close the header latches
to secure the front of the top to the wind-
shield. Catch the hook in the slot in the wind-
shield frame and then close the lever over
it so that it lays flat against the windshield
frame. If necessary, push the header forward
to make it easier to operate the latches.
When first installing the top, the
initial force requirements to oper-
ate the sun-roof and latches will be high.
It is normal for the fabric to stretch a small
amount after installation which will result in
easier operation of these components.
Windshield
Frame
Windshield
Header Latch
Catch hook in slot
Close lever over
top of hook to lay
flush with wind-
shield frame
Secure Windshield Header to Windshield
Center
Bow
Horizontal
Support Bar Center
Sport Bar
Snap Top to Center
Bow (8 Snaps)
Reach inside the vehicle and snap the 8 snaps in
the middle of the top to the Center Bow.
Snap Top Fabric to Center Bow