Rugged Ridge Exo-Top User manual

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Page 1/31
13516.02
4-Door EXO-Top Roof Rack System
OMIX-ADA® TECHNICAL SUPPORT
PHONE: M-F 8am - 5pm EST 1-800-449-6649 | EMAIL: [email protected]
FOR WARRANTY INFORMATION VISIT: www.Omix-Ada.com
The EXO-Top Roof Rack System is rated to a dynamic 300 lb, evenly distributed
load. Further loading could result in serious injury or death.

maintenance for further instructions.
This symbol will indicate parts that are in the video. Go to http://www.ruggedridge.com/

install and use instructions.
WARNING
!

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Page 2/31
Table of Contents
Important Safety Information (3)
Components List (4)
Section A - Preparing for Installation; Removal of Factory Top (8)
Section B - Cage Assembly and Installation (11)
Section C - Surrounds Assembly and Installation (13)
Section D - Bow and Slider Assembly and Installation (14)
Section E - Soft Top Assembly and Installation (19)
Operating Procedure (25)
Care and Maintenance (31)

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Your Rugged Ridge® Exo-Top is intended to increase the utility and enjoyment of your
vehicle. Before installation, please take a moment to review the following safety information
and installation instructions. Important safety information is generally preceded by one of
three signal words indicating the relative risk of injury. The signal words mean:
A hazardous situation which, if not avoided, could result in death or serious
injury. You CAN be killed or seriously hurt if you don’t follow instructions.
A hazardous situation which, if not avoided, could result in minor or moderate
injury. You CAN be moderately hurt and also may suffer property damage if
you don’t follow instructions.
Careful attention is required to this instruction or operation but does not generally
relate to personal injury. Damage to your product or other property may result if
you don’t follow instructions.
We hope you enjoy your Rugged Ridge® purchase and are here to help if you still have
questions after reviewing this safety information and instructions. See Customer Service
contacts included with your Limited Warranty.
Page 3/31
Important Information - Before You Begin
WARNING
!
CAUTION
!
These parts are required for all Hardtop owners:
Header - 68049276AB
Tailgate Bar - 55395757AC
Tailgate Bar Retainer, RH - 55395760AB
Tailgate Bar Retainer, LH - 55395761AB
Before beginning, please review the suggested list of tools required for install to ensure a
prepared and smooth install of your Rugged Ridge® Exo-Top:
-Phillips Head Screwdriver
-Flat Head Screwdriver
-Allen Keys (5 and 6mm)
-13mm Socket
-T30 Torx Bit
-Socket Wrench
-Torque Wrench
-Marker
-Hobby Knife
-Black Sealant (Permatex® or similar)

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Components List
10
12
13 14
11
9
1
2
3
4
5
8
6
7
Cage Assembly
1. Cage Base, LH (1)
2. Cage Base, RH (1)
3. Rear Cage Bar (1)
4. T Bar, Front (1)
5. T Bar, Rear (1)
6. Center Cross Bar (1)
7. Front Side Bar, LH (1)
8. Front Side Bar, RH (1)
Cage Hardware
9. M8x40 Button Head Bolt (24)
10. M10x25 Button Head Bolt (8)
11. M8 Nylon Hex Nut (24)
12. Nut Plate, Flat - M10 Hex Nut (6)
13. Nut Plate, Angled - M10 Hex Nut (2)
14. M10 Washer (8)
Page 4/31
Ensure all components and hardware are provided before beginning installation
process.

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Components List
1
2
3
4
5
6
7
8
9
Surrounds Assembly
1. Front Surround, LH (1)
2. Front Surround, RH (1)
3. Rear Lower Surround, LH (1)
4. Rear Lower Surround, RH (1)
5. Rear Upper Surround, LH (1)
6. Rear Upper Surround, RH (1)
7. Seal, LH (1)
8. Seal, RH (1)
Surrounds Hardware
9. M8x30 Knob (2)
Page 5/31

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Page 6/31
Components List
3
4
6
87
9
10 11
12 13 14
15
5
1
2
16
Slider System Assembly
1. Front Bow Assembly (1)
2. Rear Bow Assembly (1)
3. Slider Carriage Assembly, LH (1)
4. Slider Carriage Assembly, RH (1)
5. Rail (2)
Slider System Hardware
6. Front Surround Bracket, RH (1)
7. Front Surround Bracket, LH (1)
8. Mid-Rail Bracket, RH (1)
9. Mid-Rail Bracket, LH (1)
10. Rear Rail Bracket, RH (1)
11. Rear Rail Bracket, LH (1)
12. M8x18 Flathead Bolt (6)
13. M8 Nylon Lock Nut (6)
14. M8x70 Socket Cap Bolt (4)
15. M8x25 Socket Cap Bolt (2)
16. M8 Washer (6)

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
3
4
5
2
1
Soft Top Assembly
1. Soft Top Fabric (1)
2. Rear Window (1)
3. Side Window, LH (1)
4. Side Window, RH (1)
Soft Top Hardware
5. Release Clips (Carabiner) 1.5” ID (2)
Page 7/31
Components List

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Page 8/31
Section A - Preparing for Installation; Removal of Factory Top
1. Soft Top owners: Refer to owners’ manual for instructions
on lowering factory top. Once lowered, unscrew shoulder
bolts fastening it to vehicle’s roll bars. Remove canvas from
assembly.
Hard Top owners: Refer to owners’ manual for instruction on
removing factory hard top. Skip to STEP 4 once hard top is
removed.
Hardtop owners will need to purchase a factory header,
tailgate bar, and tailgate bar retainers (LH, RH).
These factory parts are required:
Header - 68049276AB
Tailgate Bar - 55395757AC
Tailgate Bar Retainer, RH - 55395760AB
Tailgate Bar Retainer, LH - 55395761AB
Note: After removing header and factory soft top, place
assembly on ground as shown on right.
Tools Needed:
Phillips head screw driver
Torx bit socket wrench (T30)
Carefully read and understand all instructions before proceeding. We recommend you save all
parts and hardware if you ever choose to re-install the factory top.

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
2. Remove front and rear door surrounds from each side of
vehicle.
3. Remove metal soft top mounting brackets attached to
roll bar in cargo area.
4. Remove screws from underside of header at each end
that attaches fabric tabs.
Do not discard screws, they are reused in later
steps.
Page 9/31
Section A - Preparing for Installation; Removal of Factory Top

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
6. Loosen all screws from top side of header. Do not
remove completely.
5. Flip header and fabric and remove screws from top of
header at each end. You will now be able to remove OE
soft top frame.
7. Release fabric from header. Keep header and all
hardware for soft top installation.
Page 10/31
Section A - Preparing for Installation; Removal of Factory Top

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Page 11/31
Section B - Cage Assembly and Installation
1. Assemble cage as shown in diagram above, adding sealant to
all joints, as shown on right.
2. Insert M8 bolts to joint areas, securing with M8 Nylon Hex Nuts
Do not fully tighten bolts at this time to allow for

Tools Needed:
5mm, 6mm Allen Keys
13mm Socket
Torque Wrench
Sealant (black Permatex, or similar)
Carefully read and understand all instructions before proceeding. Ensure all components and
hardware are provided before beginning. We recommend two people for this installation.

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
3. Align rear cage brackets with bolt holes
on tub.
4. Center Side Bar brackets with B pillar,
indicated by arrow on right.
5. Attach cage to frame using provided M10 bolts and nutplates. Angled nutplates will be used at B pillar as
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Page 12/31
Section B - Cage Assembly and Installation
ab
CAUTION
!

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Page 13/31
Section C - Surrounds Assembly and Installation
3. Install front and rear surround assembly onto

4. Bolt rear using long M8 bolt and M8 washer and
mid-point using short M8 bolt and M8 washer. Front
bolt will be installed later.
5. Repeat for other side.
1. Attach rear upper surround to rear lower surround,
placing seal in between; secure with provided M8
knob. Repeat for other side.
Tools Needed:
6mm Allen Key

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Page 14/31
Section D - Bow and Slider Installation
2. Align rear bow assembly, as shown on below, with
mounting bolts on rear roll bar, mark line approximately 2”
on fabric, and make cut to accept mounting tab of rear
bow assembly. Repeat for other side.
1. Unzip rear rollbar cover past curved point and remove
bolt; retain bolt and washer for later use. Location of bolt is
indicated by arrow shown below.
Tools Needed:
5mm, 6mm Allen Keys
13mm Socket Wrench
Marker
Hobby Knife
Carefully read and understand all instructions before proceeding. We recommend two people
for this installation.
RightLeft
Front of Vehicle

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
4. Install front and rear bow assemblies to rollbar
using factory bolts.
Test quick release function on bow before
moving to next step.
For right hand drive vehicles, front bow
assembly can be reversed so quick release is
on right side for ease of operation.
3. Align front bow assembly, as shown below, with
mounting bolts on front roll bar, mark line approximately 2”
on fabric, and make cut to accept mounting holes of front
bow assembly. Repeat for other side.
Page 15/31
Section D - Bow and Slider Installation
RightLeft
Front of Vehicle
7. Align rail brackets with correct side and placement on rails and loosely attach with M8 Flathead bolts. The
distance between front and middle holes will be greater than middle to rear.
Left
Front of Vehicle Rear of Vehicle
Right

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
8. Align mid-rail bracket with middle mounting bolt on
rollbar, mark line approximately 2” on fabric and cut
middle points for rail installation.
Page 16/31
Section D - Bow and Slider Installation
6. Install rail assembly. Slide brackets through rollbar pad
from outside of vehice as shown on right and attach using
provided M8 Long Socket Cap Bolt.
5. Align rear rail bracket on rear rollbar mounting bolt, mark
line approximately 2” on fabric, and make cut to accept
rear mounting holes of rail assembly. Repeat for other side.

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
11. Install slider carriage to rail. Cycle slider carriage
through rail and adjust bolts as necessary to ensure easy
sliding.
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side will need to be tightened.
Page 17/31
Section D - Bow and Slider Installation
9. Install front moutning hole of rail using provided M8 Short
Socket Cap Bolt.

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
13. Install header-slider carriage assembly to rails from rear
of vehicle.
14. Slide header-slider carriage assembly to front of vehicle
and latch header hooks. Latch should be centered in
middle of loop.
15. Ensuring cage is centered between front and rear
surrounds, tighten all surround and rail bolts.
16. Cycle header-slider assembly to ensure smooth
operation and correct assembly. Remove header-slider
carriage assembly to prepare for soft top installation.
Page 18/31
Section D - Bow and Slider Installation
12. Install slider carriage assembly to header using factory
screws from top of header; slider carriage assembly will
face inward as shown. Do not install lower factory screws.

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]
Page 19/31
Section E - Soft Top Assembly and Installation
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
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Tools Needed:

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

Copyright © 2015 Omix-Ada®, Inc.
460 HORIZON DR. SUITE 400 | SUWANEE, GA 30024 | PHONE: [phone] | FAX: [phone] | [email protected]

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



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Section E - Soft Top Assembly and Installation