How To: Roof and Door Removal - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > TJ Jeep Wrangler Forum > TJ General Discussion Forum

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 03-09-2010, 11:59 PM   #1
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,639
How To: Roof and Door Removal

I figured the WF community has done a lot for me, so I might as well give back. Summers coming quick and I know they're going to be some newbies asking how to remove their doors or roof and why it's impossible to do! So while I was taking off my own doors and roof I decided to do a write-up.

Now this is for a 1999 Wrangler, but I assume the variances between TJ/LJ and 1997-2002 and 2003+ aren't too much different. This is also for the full steel doors.

Door Removal

Materials
  • PB Blaster
  • Wrench or pliers
  • Hydraulic Lift (optional)
  • 2x4 lumber

I will say this right now. If you don't have a hydraulic lift, go out and purchase one. It will become one of the most used tools within your Jeep maintenance, I guarantee. Plus, it makes this job a piece of cake.

Locate the the small nuts at the bottom of the door hinges. Spray some PB Blaster onto the nuts and wait fifteen minutes.



Use the wrench or pliers to unscrew the nuts CLOCKWISE if you are facing DOWN at the hinges. Take care not to scratch the body of the Wrangler. It is easier to paint the nuts then paint the Jeep.

Then roll down the window. It's added protection against flexing and shattering.

Pull straight up on the doors with the most comfortable grip. I find putting one arm over the window and holding onto the inside strap and the other arm at the bottom with the window frame resting on my shoulder is the easiest way to set the door.

If you have trouble lifting the door out, rather then exert excessive energy, do the following.

Find yourself a piece of lumber and cut a small notch about 3/4" deep.



Place it on the hydraulic-lift with the door frame sitting the notch of the wood. You can put a towel between the lumber and the door to protect it from scratching. I wasn't too concerned. Try to get it as close to the bottom of the hinges or the inside of the door.



Lift up and the door should start to come out of the hinges. Be sure not to let it come all of the way out before finishing the job yourself. You may want to cut away the bottom of the pins on the door so you don't have to worry next time about removing the nuts.


Hardtop Roof Removal

Materials
  • T40 Star Bit
  • 3/8" driver (or your choice)
  • Two strong people (I cannot stress this enough)



My materials.

Begin by climbing into the backseat and locating three T40 bolts on each side.



Depending on your vehicles past, there may not be all six present (or even four present ).



Some of the bolts (if not all) have a nut behind them, so be sure to put your free hand underneath to catch anything that falls. Losing those would be lame.

Then take your sun visors and pull them back revealing two beautiful latches. Pull up on each latch and remove the notch piece from the channel lock.



Now here comes the tricky part. The hardtop weighs about 150lbs. I'd recommend not dropping it or be prepared for the glass to shatter. Easiest thing to do is open the tailgate, lift up the rear window, and then close the tail gate.

Then, have two people stand on each side of where your doors used to be (they're off right ). Push UP to pop loose the roof, but don't remove it just yet. Once your sure the roof is free from the front, being to lift up right in center where the rear windows end. Grab with the other hand right below the middle of the rear window glass and walk towards the back of the Jeep. This way, the weight is distributed and not awkward.

Now ENJOY and go get 'er muddy!


burton160w is offline   Quote Quick Reply
Old 03-10-2010, 12:18 AM   #2
Jeeper
 
YAHAHA's Avatar
 
Join Date: Jan 2010
Posts: 774
Good writeup. Don't forget to unplug the electronics for the wiper/defroster and the washer fluid hose first! Trying to remove the hardtop with these still connected will ruin your day. You can also use an allen wrench if you can't find your torx bit.

YAHAHA is offline   Quote Quick Reply
Old 03-10-2010, 12:20 AM   #3
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,639
Thanks! Added to the write-up. I didn't think about this because I don't have a rear wiper or defroster on mine.
burton160w is offline   Quote Quick Reply
Old 03-10-2010, 12:29 AM   #4
Jeeper
 
APPSTATEwrangler's Avatar
 
Join Date: Oct 2009
Location: High Point, NC
Posts: 575
and ya have to do something about those overhead lights with the doors off.
i just take out the fuse, but you can buy some cheap mods also.
__________________
04 Forest Green Sport. 32" Geolander AT-S w/ spidertrax spacers , 2" Skyjacker spacer lift w/ Hydro Shocks, JKS quick discos, RR tube brush guard, 10" Memphis Sub w/ custom box under rear seat, RR seat covers, and a sh** ton of good ole' N. Carolina red clay.
APPSTATEwrangler is offline   Quote Quick Reply
Old 03-10-2010, 07:12 AM   #5
Jeeper
 
Kilroy's Avatar
 
Join Date: Dec 2009
Location: Southern California
Posts: 570
The bolts that hold the top on screw into threaded, rectangular shaped pieces of 3/16" thick steel. These are original equipment and are used instead of nuts so they will not spin when tightening or loosening the bolts. You do have to catch them when removing the bolts. Esecially the ones up front, else they will fall where they cannot be reached. And many Jeeps do not have the plates because they were lost, or didn't come with the purchase of a used hardtop.
__________________
Patience is a waste of time...
Kilroy is offline   Quote Quick Reply
Old 03-10-2010, 10:08 AM   #6
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,639
Yea, mine were a hodgepodge of nuts. Wing-nuts, hex-nuts, and the rectangle nuts. Plus big nuts.

Unfortunately, I can't do any editing of the OP if a mod would like to help out.
burton160w is offline   Quote Quick Reply
Old 03-10-2010, 10:37 AM   #7
Jeeper
 
Join Date: Mar 2009
Location: Bixby, Oklahoma
Posts: 439
Quote:
Originally Posted by burton160w View Post
Yea, mine were a hodgepodge of nuts. Wing-nuts, hex-nuts, and the rectangle nuts. Plus big nuts.

Unfortunately, I can't do any editing of the OP if a mod would like to help out.
Of your hodgepodge of nuts, and besides the factory rectangular nuts, which have worked best for you. I have (2) original torx head bolts, (3) original rectangular nuts, and the others are just small, galvanized bolts with hex nuts. I'm lucky though, because the nuts don't spin on me when I am removing them.
I'm wondering if the wingnuts would work good if you feed the bolt in from the bottom, with the wing nut on top of the tub rail. They really don't need to be much more than finger tight, and a wing nut allows that extra bit of leverage to tighten up good.
Anyone ever tried this?
__________________
At some point during jeep ownership, you will BUST A NUT!!!
T-BONE N BIXBY is offline   Quote Quick Reply
Old 07-13-2010, 02:25 PM   #8
Newb
 
Join Date: Jul 2010
Posts: 6
Anyone have any ideas on what could be causing my 2003 hardtop to not come off after I removed all 6 bolts, unhinge the windshield latches and disconnect the rear window defogger? I just bought this thing and I don't think the top was ever taken off. I tried wedging a chisel between the top and side panel, but I don't want to force it too much. The top portion at the windshield releases but it seems there is something in the middle of the top that just won't let go. Help please!
vasoxjeep is offline   Quote Quick Reply
Old 07-13-2010, 02:38 PM   #9
Jeeper
 
yjkid95's Avatar
 
Join Date: Jan 2010
Location: Great Lakes, Illinios.
Posts: 1,849
i just leave the bolts off my doors when the doors are latched shut they arent going to bounce off or anything plus as long as its not raining the doors are always off typically from the end of april to the end of october and i just unplugged the overhead light at the door surrounds.
yjkid95 is offline   Quote Quick Reply
Old 07-13-2010, 02:43 PM   #10
Trail Mom

WF Supporting Member
 
Kate's Avatar
 
Join Date: Aug 2008
Location: Scotts Hill, TN
Posts: 2,864
vasox - there is a foam weatherstrip between the top and the tub.
It sometimes sticks to the tub making it hard to break loose.

Sounds to me like you got all of the fasteners loose. If it were me I would spray it down with some windex or even WD 40 (or something) in the hopes that it would help get it started.

Otherwise you might crawl up in the back of the Jeep and put your shoulders under the center of the top and push gently but firmly. Pushing from this position will get it started breaking loose on both sides and with luck get it to come off.

Better still, if you can get someone to help you, stand on the ground and both push up at the same time. Lift Front to back.

I wouldn't use a chisel or other metal instrument for fear of cracking the top or scratching the paint. Maybe a plastic putty knife but then you'll likely have to replace that weatherstrip. You'll prolly have to anyway though because it could tear when you finally get it going.
__________________
06 Rubi with some sort of double ended, chrome knobbed, cross threaded, infinitely adjustable, frequently breakable, worn out flammywhammers zip tied onto it.
It used to be a jeep thing... til that sh!t broke!
Kate is offline   Quote Quick Reply
Old 07-13-2010, 02:53 PM   #11
Newb
 
Join Date: Jul 2010
Posts: 6
Thanks Kate. I have only owned soft tops in the past, so I didn't want to force the issue, thinking I might break something off. But in reading other posts and now yours, its obvious that I haven't missed anything as far as bolts, etc go. I just need to apply a little more pressure with a second person on the opposite side of the top. Thanks again.
vasoxjeep is offline   Quote Quick Reply
Old 07-13-2010, 03:49 PM   #12
Trail Mom

WF Supporting Member
 
Kate's Avatar
 
Join Date: Aug 2008
Location: Scotts Hill, TN
Posts: 2,864
My pleasure!
I hope it helps, keep us posted!
__________________
06 Rubi with some sort of double ended, chrome knobbed, cross threaded, infinitely adjustable, frequently breakable, worn out flammywhammers zip tied onto it.
It used to be a jeep thing... til that sh!t broke!
Kate is offline   Quote Quick Reply
Old 07-13-2010, 03:59 PM   #13
Jeeper
 
TjTheo's Avatar
 
Join Date: Mar 2010
Location: Bloomingburg, NY
Posts: 908
I dont think the jack to push the door out is a good idea. iv'e heard of people bending their hinges like that.
__________________
If you dont get stuck, you're not trying hard enough.

98 tj 4.0 5 speed aka "rosie"
TjTheo is offline   Quote Quick Reply
Old 07-13-2010, 04:00 PM   #14
Jeeper
 
yjkid95's Avatar
 
Join Date: Jan 2010
Location: Great Lakes, Illinios.
Posts: 1,849
Just another thought to add too kates post when you put down the new weatherstripping spray a little silicone on it so that it wont glue your top to the tub again and just spray the silicone on it whenever you notice that its looking a little dry to prevent it from happening again.
yjkid95 is offline   Quote Quick Reply
Old 07-13-2010, 06:55 PM   #15
Newb
 
Join Date: Jul 2010
Posts: 6
Silicone, good idea. I'll use that when/if I get the damn top off.
vasoxjeep is offline   Quote Quick Reply
Old 07-13-2010, 07:10 PM   #16
Jeeper
 
SurfKaster's Avatar
 
Join Date: Mar 2010
Location: St. Augustine FL
Posts: 1,633
Eye bolt through rafter, rope pulley, & a couple of ratchet straps gets the job done for me.

SurfKaster is online now   Quote Quick Reply
Old 10-04-2010, 10:14 PM   #17
Jeeper
 
robbiecc's Avatar
 
Join Date: Sep 2010
Posts: 771
what's the strap in the back going to??
robbiecc is offline   Quote Quick Reply
Old 10-04-2010, 10:50 PM   #18
Jeeper
 
InvertChaos's Avatar
 
Join Date: Sep 2010
Location: NoVa
Posts: 7,918
I don't know about you guys but I can handle the doors with out a jack and I'm only 6' 165lbs...
InvertChaos is online now   Quote Quick Reply
Old 10-05-2010, 12:12 AM   #19
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,639
It's when you first remove them a lot people are finding that corrosion had made it difficult to pull up and lift the doors off. The jack helps pop the doors off. I can lift 'em no problem, but my passenger sided wouldn't lift out the first time.
__________________
It's got a Willy's body, a Chevy engine, Ford axles, GM transmission, and Dodge steering components... it must be a Wrangler.
burton160w is offline   Quote Quick Reply
Old 10-05-2010, 08:44 PM   #20
Jeeper
 
GoldTJ's Avatar
 
Join Date: Jun 2010
Location: Southwestern Tennessee
Posts: 392
Images: 1
@robbiecc-I hope it is attached to the rear of the top,otherwise it will be SEVERELY unbalanced and tip rearward and shatter the rear window-simple physics!
GoldTJ is offline   Quote Quick Reply
Old 10-05-2010, 10:37 PM   #21
Jeeper
 
robbiecc's Avatar
 
Join Date: Sep 2010
Posts: 771
Quote:
Originally Posted by GoldTJ View Post
@robbiecc-I hope it is attached to the rear of the top,otherwise it will be SEVERELY unbalanced and tip rearward and shatter the rear window-simple physics!
i see the one in front going from side to side and the front/back one is hooked to it-but what's it hooked on in back-i can't think of anything to hook it up to back there
robbiecc is offline   Quote Quick Reply
Old 10-05-2010, 10:39 PM   #22
Jeeper
 
robbiecc's Avatar
 
Join Date: Sep 2010
Posts: 771
rear glass off maybe??
robbiecc is offline   Quote Quick Reply
Old 01-10-2011, 02:15 AM   #23
Newb
 
Join Date: Jan 2011
Location: Hooksett, NH
Posts: 3
CAN you use an allen wrench? I thought you had to use a Torx to avoid stripping...?
ABJeep is offline   Quote Quick Reply
Old 01-10-2011, 05:41 AM   #24
Jeeper
 
robbiecc's Avatar
 
Join Date: Sep 2010
Posts: 771
i would use the correct tool-depending if they have been changed or not will decide what to use.

I used a slightly modified version of this lift-i used 4 rachet straps and lifted/replaced the hard top by myself. Was worried after i removed it since rachet straps only 'rachet' one way but the top is light enough that you can release the straps a few inches at a time to get it down( and i took it all the way to the ceiling)
I now have my rolled up soft top hanging from 2 of the straps.

robbiecc is offline   Quote Quick Reply
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off




Download our Mobile App

» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 10:47 AM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC