Bestop 54863 Installation Instructions Manual Download Page 7

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Installation Instructions - Trek Top PRO 2

Section 1

Install Cable or Spring Bracket to Window Carrier

Step 1

510.56
494.01

10mm Wrench

4mm Allen

Wrench

510.55
257.93

547.91

Window Carrier - Right

Part #510.56

Qty. 1

Window Carrier - Left

Part #510.55

Qty. 1

M6 Nylon Lock Nut

Part #494.01

Qty. 2

M6 Flat Washer

Part #257.93

Qty. 2

M6 Screw

Part #517.63

Qty. 2

517.63

Hardware

Tools

Step 1

Install a Cable Bracket #547.91 onto each

Window Carrier #510.55 & 510.56.

Attach the Cable Bracket using the hole

in the Window Carrier closest to the front

(the end with the molded cap).
Install the M6 Screw #517.63 and Flat

Washer #257.93 from the top and the M6

Nylon Lock Nut #494.01 from underneath

the Window Carrier and tighten.

Cable or Spring

Bracket

Part #547.91

Qty. 2

M6 Nylon

Lock Nut

M6 Screw

M6 Flat Washer

Window Carrier

Summary of Contents for 54863

Page 1: ...t rely in any way on the components of this product to protect against injury or death in the event of an accident Never operate the vehicle in excess of manufacturer s specifications Read and follow...

Page 2: ...35mm Screw Part 514 62 Qty 2 M6 x 25mm Screw Part 431 62 Qty 12 M6 Nylon Lock Nut Part 494 01 Qty 22 M6 Flat Washer Part 257 93 Qty 22 M6 x 14mm Screw Part 517 63 Qty 10 M8 x 20mm Screw Part 493 96 Q...

Page 3: ...Installation Instructions Trek Top PRO 2 Sections 1 2 Window Carriers Cable Bracket Rear Brackets Section 3 Rear Door Surrounds Window Carrier Left Part 510 55 Qty 1 Rear Door Surround Right Part 486...

Page 4: ...hown 544 19 Left Qty 1 of each Strut Bracket Left Part 509 63 Qty 1 Strut Bracket Right Part 509 64 Qty 1 Halo Right Part 509 76 Qty 1 Halo Left Part 509 77 Qty 1 Halo Frame Part 509 82 Qty 1 Halo Cen...

Page 5: ...ctions Trek Top PRO 2 Sections 11 to 15 Seals Struts Sections 20 to 24 Center Rear Arch Bows 2 Bow Assembly Halo Seal Long Part 510 17 Qty 1 Strut Part 510 16 Qty 2 Rear Seal Short Part 511 87 Qty 1 U...

Page 6: ...for installation Page number in Installation Guide Installation Instructions Trek Top PRO 2 Foam Tape Strips Qty 2 Part 417 43 Foam Seals Qty 1 per side Part 457 76 R 457 77 L Jumper Harness Qty 1 Par...

Page 7: ...t Washer Part 257 93 Qty 2 M6 Screw Part 517 63 Qty 2 517 63 Hardware Tools Step 1 Install a Cable Bracket 547 91 onto each Window Carrier 510 55 510 56 Attach the Cable Bracket using the hole in the...

Page 8: ...Unzip the upper rear and rear leg sport bar covers and locate the upper sport bar bolt Use a 13mm wrench to remove the bolt and set it aside for later use Repeat on both sides of the vehicle Cut two h...

Page 9: ...nt the Rear Brackets 510 96 and 510 97 to the sport bar on each side of the vehicle through the slits cut in the sport bar cover Tighten the bolts just snug so that the bracket can be adjusted in the...

Page 10: ...e pin in the bottom of the Rear Door Surround 486 66 into the hole in the belt rail behind the rear door opening Press the channel along the top of the Rear Door Surround around the the horizontal spo...

Page 11: ...n the right Front Door Rail 479 86 on the sport bar above the passenger side door and press it into place on the sport bar Secure the Front Door Rail in place with one 1 M8 x 75mm Knob 478 90 at the f...

Page 12: ...asher Part 257 92 Qty 4 M6 Nylon Lock Nut Part 494 01 Qty 4 M6 x 14 Screw Part 517 63 Qty 4 10mm Wrench 4mm Allen Wrench Step 1 Install the RIght Window Carrier 510 56 to the Rear Bracket The plastic...

Page 13: ...Part 509 82 Qty 1 M6 Nylon Lock Nut Part 494 01 Qty 2 Step 1 Step 2 Install the Halo Frame 509 82 to the Window Carrier Secure each Halo Frame to the Window Carrier using two 2 M6x14 Screws 517 63 and...

Page 14: ...nstall Halo Center Step 1 Hardware 509 80 Halo Center Part 509 80 Qty 1 Step 1 Position the Halo Center 509 80 on the Halo Frame No fasteners are required for this step You may need assistance to hold...

Page 15: ...6 Flat Washers 257 93 from the out side and two 2 M6 Nylon Lock Nuts 494 01 from the inside in the outer most holes on each side Tighten screws just snug at this time so that the Halo can be adjusted...

Page 16: ...M6 Nylon Lock Nut Part 494 01 Qty 4 Step 1 Step 2 Hook each Strut Bracket 509 63 and 509 64 under the vehicle belt rail inside the vehicle and rotate the bracket up Secure each Strut Bracket to the H...

Page 17: ...433 98 493 96 434 12 Hardware Step 1 Use two 2 M8x20 Screws 493 96 four 4 M8 Flat Washers 433 98 and two 2 M8 Nylon Lock Nuts 434 12 to secure the Halo to the vehicle belt rail It may be easier to ins...

Page 18: ...ion 12 Install Halo Seal Step 1 510 17 Hardware Halo Seal Long Part 510 17 Qty 1 Step 1 Install the Halo Seal 510 17 on the Halo Start at the bottom on each side and work toward the center Align the b...

Page 19: ...outside and two 2 M6 Nylon Lock Nuts 494 01 from the inside in holes for the hinges on each side If the hinge holes don t align insert a screwdriver in the hole to align the parts Take a close look at...

Page 20: ...To Remove Step 1 510 16 Hardware Flat Blade Screwdriver Step 1 To Remove To install the Struts 510 16 1 Secure the top tube section of each Strut to the Rear Window Glass by pressing the end onto the...

Page 21: ...RO 2 2018 Bestop Inc Section 15 Install Rear Seal Step 1 511 87 Hardware Rear Seal Short Part 511 87 Qty 1 Step 1 Install the Rear Seal 511 87 on the bottom of the Rear Window Glass Start on the outsi...

Page 22: ...anel Seals Step 1 514 04 514 05 Hardware Upper TG Panel Seal Part 514 04 Qty 2 Lower TG Panel Seal Part 514 05 Qty 2 Step 1 Install the TG Panel Seals 514 04 and 514 05 on the tailgate panel The Upper...

Page 23: ...ts on sport bar holding Rear Brackets Zip sport bar covers closed Tighten all Halo frame fasteners including lower Halo Strut Bracket and Halo lower screws Passenger side fastener locations shown Repe...

Page 24: ...g up in the middle of the bottom of the Bow 3 Push the opposite end of the Bow inward to flex the Bow and insert it into the slot in the opposite side of the Window Carrier 1 Insert one end of the Top...

Page 25: ...7 43 457 77 Foam Tape Strips Part 417 43 Qty 1 per side Foam Seals Part 457 76 Right Part 457 77 Left Qty 1 per side Step 1 Step 2 Peel the backing off the Foam Tape Strips 417 43 and install them on...

Page 26: ...nd the farbic draped forward over the Jeep hood You may want to protect the finish of the Jeep by putting a blanket across the Jeep Hood Attach the right Side Bow to the Right Sunrider Pivot Bracket 5...

Page 27: ...ivot Bracket and slit the sport bar cover to allow this tab to protrude from the cover Repeat on the left side of the Jeep using the 541 87 Pivot Bracket Step 1 541 87 541 88 541 18 2 Bow Assembly Har...

Page 28: ...526 76 Qty 2 Right Side Side Bow Right Side 2 Bow Leg Tools 8mm Socket Ratchet 3mm Allen Wrench M5 Flat Washer Part 575 27 Qty 2 Secure the 2 Bow to the right Side Bow using one 1 5x35mm Machine Screw...

Page 29: ...1 Lay the Top Fabric back across the top of the Jeep Open the Sunrider by folding the Header back Run the spring cable under the Door Surround shoulder screw and hook it into the Cable Bracket on the...

Page 30: ...indow Carrier and slide the tube on the top of the Right Side Window into the slot in the Window Carrier Repeat on the left side of the vehicle Roll the window retainer into the vertical slot on the f...

Page 31: ...om of the window Tuck the retainer under the vehicle belt rail You can adjust the window front to back if needed but the fabric will be tight Repeat on the both sides of the vehicle Install the rear c...

Page 32: ...tart at the bottom and roll the retainer into the slot in the Rear Halo Work up from bottom to top Repeat Steps 1 5 on the other side of the vehicle Step 5 Start at the bottom and roll the retainer in...

Page 33: ...c Step 2 Step 1 Start in the middle and roll the r etainer into the slot in the Rear Halo above the Rear Window hinges Operation is made easier if the Sunrider is open for both installation and remova...

Page 34: ...Installation Instructions Trek Top PRO 2 2018 Bestop Inc Section 27 Install Top Fabric cont Step 3 Engage rear corner hook and loop on both sides of the vehicle Step 3...

Page 35: ...PRO 2 2018 Bestop Inc Section 28 Close the Top Step 1 Step 2 Close the Sunrider Hook the latches on the windshield header into the loops on the wind shield Do not close the latch Repeat on the opposit...

Page 36: ...the latches on both sides of the windshield header Inspect the fabric fit to the vehicle The Trektop PRO hardware is designed for adjustment You may find it helpful to perform some adjust ments to imp...

Page 37: ...or Rear Glass Original Soft Top Only Original Soft Top Only Purchase a MOPAR wiring harness not included and install according to MOPAR directions Model Years 2007 2010 82210215 Model Years 2011 witho...

Page 38: ...Qty 1 Attach Harness to Rear Glass heater grid terminals and route the wiring back to the existing OE harness Use the P clips and the screws provided in the harness kit to route the wires Remove any c...

Page 39: ...Installation Instructions Trek Top PRO 2 2018 Bestop Inc Section 30 Available Optional Accessories 5485801 Rear Wiper Motor Kit 5485701 Heater Grid Only Harness Sold Separately Sold Separately...

Page 40: ...become stiff and will crack Cracks caused by misuse in cold temperatures are not covered under warranty Zippers Keeping zippers cleaned and lubricated with Bestop s Zipper Cleaner part no 11206 00 wi...

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