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How to Install Smittybilt Safari Hard Top on your Wrangler

Installation Time

20 minutes

Extreme Terrain
Shop Parts in this Guide
Parts IncludedQty
Hardtop1
Door Corner Seal2
Footman Loop2
5/16 x 1”Mounting Bolt6
Mounting Nut6
Flat Washer6

Step 1: If your vehicle is/was equipped with a softop remove all associated hardware. (Bow assembly, tail gate bar, tailgate bar clamps, ect) Do not remove the front Mucket seals behind the door openings. (Fig A) *Once removed make sure vehicle is square. (The distance is the same on driver and passenger side from the top edge of the windshield frame straight back to top edge of body tub in rear corners)

Step 2: With assistance carefully place the top onto the vehicle lining up the holes in the top and the holes on the body. (Fig B) NOTE: It is recommended to use 4 people to do this. You may need to pull down the side section between the doors (JK 4 Door) in order to make sure it fits into the OE seals properly. (Fig C, D)



Step 3: Attach top using included the hardware. (Fig E) Do not fully tighten at this time. NOTE: Nuts are included if your vehicle does not have the OEM nut plates. Make sure top is aligned evenly on both sides of the vehicle and with the rear door opening. (Fig F) Secure all rear section (top and bottom) mounting bolts at this time. Use a criss-cross pattern when tightening (Fig G, H) It may be helpful to have an assistant push from the outside of the top inwards to help align holes. NOTE: Due to variances in vehicle manufacturing if a hole on the top is slightly off you can easily open the hole up with a drill bit.



Step 4: Close window and make sure gap on each side of window between glass and top is even. (Fig I) If window needs slight adjustment you can loosen the hinge bolts to make needed adjustments.


Step 5: Pull the sun visors back and remove the footman loop attached to the top of the windshield frame using a #25 torx bit. (Fig J)

Step 6: Install the included footman loops using the previously removed hardware. (Fig K)


Step 7: IMPORTANT- When placing the front section on; make sure to “Tuck” in the front OEM corner seals (Fig L,M,N)


NOTE: The instructions for installing this top must be followed and done every time as described when the top is removed and re-installed.



Step 8: Check seal on top to make sure it’s even. (Fig O) Secure front section of top to vehicle by attaching the latches to the front footman loops on the windshield frame. (Fig P) NOTE: Do not over tighten, tighter does not always equal better. The clamp on the latch can be adjusted by turning the nut counter clockwise and the hook clockwise. (Fig Q)

Step 9: Pull back top rear corner seal from the front door. Making sure door is clean, peel back the paper from the seal and place on door. (Fig R)


Step 10: Installation is now complete. (Fig S, T)


The Safari tops come Defender Roof Rack ready, simply unscrew the s/s allen cap bolt and remove along with washer that are on the top (Fig U) and install coordinating mount kits and rack following the mount kit instructions. (Fig V-Y)



CARE AND MAINTENANCE

Wash and clean using a soft cloth and non abrasive soap and water. DO NOT use automotive past wax or something similar that use fillers like Armor all. It is recommend to use something like Auto Glym plastic conditioner. It contains weather resistant resin polymers to help reduce the aging effect cause by sunlight, water and other elements. It is available at most automotive detail outlets.

Note: Only use a micro-fiber type of cloth for the upper sky windows.

ADJUSTMENTS / INSTALLATION TIPS

Due to variations in construction and assembly procedures during vehicle manufacturing and also dealing with a vehicle that has been on the road for almost 5-10 years, in most cases you will be required to make some sort of adjustments.

1. In many instances the actual steel door on the vehicle will need to be adjusted. You can make adjustments to the lower doors by slightly loosening the door hinge bolts using a T40 torx bit and reposition the door for an improved fit. NOTE: Use caution when doing so. When loosened the doors can move forward, backwards, up and down.

2. Make sure top is sitting in the factory seals correctly. Make sure the seals are not folded or smashed in the wrong position.

3. If the back side of the door is hitting the top, unhook the windshield latches, loosen the rear mounting bolts and then push top backwards. Re-tighten the rear bolts and re adjust front latches.

4. Make sure vehicle is square in some cases the windshield frame may need to be adjusted. an 1/8” can make a big difference in regards the angles. This would be done by loosening the windshield hinge/bracket bolts. With an assistant pulling or pushing the frame (depending on which way you need to go) retighten the bolts.

5. If the top of the door is hitting the top, you can shim the top. Unlatch the front of the top and remove the rear bolts. You can shim top simply by placing the needed amount of flat washers over the mounting holes on the vehicle and then replace top over and reattach bolts.

6. The OEM seals may need to be changed. Depending on the condition either one or all of the rubber seals needed for a good fit may need to be replaced. (Full Steel Door Seal, Cowl Rubber, Windshield header Seal.) Signs of a seal needing replacement are; worn, dry or flattening of the rubber.