Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Convertible Top

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TOP COVER REPLACEMENT



Shadow/Sundance Convertible

See Figure 1

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Fig. Fig. 1: Cutaway view of the convertible top on the Shadow and Sundance models

Review the complete service procedure before starting this repair.

  1. Open rear window and position glass, as flat as possible, in the drop well area.
  2.  
  3. Lower the convertible top.
  4.  
  5. Remove the rear seat cushion and back.
  6.  
  7. Remove the quarter trim panels.
  8.  
  9. Remove the quarter glass assemblies.
  10.  
  11. Raise the convertible top to mid-point position.
  12.  
  13. Remove the screws holding the cover retainer to the top header. Separate the retainer from the header.
  14.  
  15. Separate the convertible top cover from the adhesive on the top header.
  16.  
  17. Open the trunk lid. Remove the screws holding the rear deck filler panel to the rear deck below the rear window. Mark the screw locations before removal to aid installation. The rear deck filler panel applies pressure to the top cover to eliminate wrinkles.
  18.  
  19. From in the luggage compartment, remove the nuts and bolts holding the lower top tack strip to the deck and quarter panels. Lift the sling well upward to gain access to the fasteners.
  20.  

Do not damage the painted surface when separating the tack strip from the mounting location.

  1. Separate the tack strip from the deck and quarter panels and remove the staples holding the top cover. Leave the rear window skirt, pads and drop well attached to the tack strip.
  2.  
  3. Pull the top cover from the adhesive in the quarter glass weatherstrip channel.
  4.  
  5. Remove the rivets holding the top cover rail tension cables to the top header. Pull the tension cables from the rear of listing pockets on the top cover.
  6.  
  7. Remove the screws holding the top cover fastener strip to the center roof bows. Separate the top cover roof bows and pull the retainers from the listing pockets on the top cover.
  8.  
  9. Fold the top cover so that all the material is above the rear roof bow. Slide the rear top cover retainer to one side from the rear roof bow channel. Separate the convertible top cover from the vehicle.
  10.  

To install:
  1. To install the convertible top cover to the vehicle reverse the removal procedure steps. Use contact adhesive to secure the top cover to the header and quarter glass weatherstrip channels. Fold the replacement convertible top along the center line and mark. Measure and mark the center line of header, center bow and tack strip. Install the top cover from the center line out. Do not over stretch the top cover when removing the wrinkles. Allow for some shrinkage.
  2.  
  3. Install the new top cover onto the vehicle.
  4.  
  5. Slide the rear top cover retainer into the roof bow channel.
  6.  
  7. Install the top cover bows and pull retainers onto the listing pockets on the top cover.
  8.  
  9. Install the tension cables on the rear of the listing pockets on the top cover.
  10.  
  11. Apply new adhesive to the quarter glass weatherstrip channel and install the top cover.
  12.  
  13. Position the tack strip on the top cover and install new staples, then install the tack strip on the deck and quarter panels.
  14.  
  15. Install the lower top tack strip on the deck and quarter panels, then install the retaining nuts.
  16.  
  17. Install the rear deck filler panel on the rear deck below the window. Use the alignment marks made during removal to position it.
  18.  
  19. Apply new adhesive to the top header, then install the top cover.
  20.  
  21. Install the retainer on the header, then install the retaining screws.
  22.  
  23. Lower the top.
  24.  
  25. Install the quarter glass assemblies.
  26.  
  27. Install the quarter trim panels.
  28.  
  29. Install the rear seat cushion and back.
  30.  
  31. Raise the top and check for wrinkles and correct positioning. If there are excessive wrinkles or the top is positioned incorrectly, it must be removed and installed again.
  32.  
  33. Check the convertible top operation.
  34.  

LeBaron Convertible

See Figures 2, 3, 4 and 5

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Fig. Fig. 2: The dimensions of the metal skeleton of the convertible top-LeBaron Convertible



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Fig. Fig. 3: The tack strip mounting position



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Fig. Fig. 4: The third roof bow and related components



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Fig. Fig. 5: The headlining attaching points of the convertible top

  1. Release the folding top latches and allow the cover to relax.
  2.  
  3. Remove the headlining.
  4.  
  5. Disengage the snaps holding the top storage sling to the rear deck and quarter panels.
  6.  
  7. Position the sling aside.
  8.  
  9. Remove the bolts holding the rear tack strip to the inner deck panel.
  10.  
  11. Separate the rear tack strip from the deck panel.
  12.  
  13. Remove the bolts holding the side tack strips to the inside of the quarter panels.
  14.  


WARNING
Cover all painted and upholstered surfaces to avoid damage while performing the following operations.

  1. Separate the tack strips from the quarter panels.
  2.  
  3. Reposition the tack strips above the rear deck and quarter panels.
  4.  
  5. Using a grease pencil, mark the location of the outer top cover on the rear tack strip to aid installation.
  6.  
  7. Remove the staples holding the top cover to the rear tack strip.
  8.  
  9. Fold the rear of the top cover, tack strips and rear window up and over the third (rear) roof bow.
  10.  
  11. Unzip and separate the rear window from the vehicle.
  12.  
  13. Mark the location of the top cover hold-down listing on the third roof bow.
  14.  
  15. Remove the staples holding the top cover listing to the third bow.
  16.  
  17. Remove the screws holding the roof rail tension cable springs to the roof rear rail behind the quarter glass opening.
  18.  
  19. Pull the quarter glass weather strips from the roof rail channels.
  20.  
  21. Remove the screws holding the roof rail channels to the roof rails.
  22.  
  23. Separate the roof rail channels from the vehicle.
  24.  
  25. Separate the top cover listing from the adhesive on the roof rail.
  26.  
  27. Lower the folding top to the mid-point.
  28.  
  29. Pull the top header weatherstrip from the retaining channel. Separate the first 2 in. (51mm) of the weatherstrip from the roof rail channels.
  30.  
  31. Remove the screws holding the weatherstrip channel to the top header.
  32.  
  33. Separate the channel from the top header.
  34.  
  35. Remove the staples holding the top header feature strip to the top header.
  36.  
  37. Separate the feature strip from the header.
  38.  
  39. Mark the location of the top cover on the top headliner.
  40.  
  41. Remove the staples holding the top cover to the header.
  42.  
  43. Close the folding top, but do not latch it.
  44.  
  45. Remove the rubber plugs holding the roof rail tension cable ends into the key-hole slots in the roof rails.
  46.  
  47. Disengage the roof rail tension cables from the roof rails.
  48.  
  49. Pull the tension cables from the rear of the pockets on the back of the top cover.
  50.  
  51. Remove the screws holding the top cover retainer rod to the second roof bow.
  52.  
  53. Separate the retainer rod from the second roof bow to the first roof bow.
  54.  
  55. Remove the screws holding the top cover retainer rod to the first roof bow.
  56.  
  57. Separate the retainer rod from the first roof bow.
  58.  
  59. Separate the top cover from the vehicle.
  60.  
  61. Pull the retainer rod from the listing pockets on the back of the top cover.
  62.  

To install:
  1. On the old top cover mark a line from the top of the quarter glass opening to the center of the rear glass opening on each side of the top.
  2.  
  3. Using a suitable cutting tool, cut the rear quarter sections off of the old top.
  4.  
  5. Mark the locations of the old top cover on the side tack strips.
  6.  
  7. Remove the staples holding the old top cover to the side tack strips.
  8.  
  9. Using quarter sections cut from the old top cover as a pattern, mark the lower tack strip edge of the new top to the same size and shape as the old top.
  10.  
  11. Trim the excess material from the new top cover.
  12.  
  13. Position the side tack strips under the edge of the new top and align the index marks.
  14.  
  15. Install staples 4 in. (10cm) apart to hold the top cover to the side tack strips.
  16.  
  17. Install the retainer rod in the listing pockets on the back of the top cover.
  18.  
  19. Position the new top cover over the top bows on the vehicle and center the top from side-to-side.
  20.  
  21. Mate the retainer rod to the first roof bow.
  22.  
  23. Install the screws to hold the top cover retainer rod to the first roof bow.
  24.  
  25. Mate the retainer rod to the second roof bow.
  26.  
  27. Install the screws to hold the top cover retainer rod to the second roof bow.
  28.  
  29. Route the roof rail tension cables through the rear of the pockets on the back of the top cover.
  30.  
  31. Connect the roof rail tension cables to the key-hole slots in t he roof rails.
  32.  
  33. Install rubber plugs to hold the roof rail tension cable ends into the key-hole slots in the roof rails.
  34.  
  35. Apply suitable contact adhesive to the roof rail rear of the quarter glass opening and back of the top cover hold-down listing.
  36.  
  37. Stick the top cover listing to the roof rail.
  38.  
  39. Place the roof rail weatherstrip channel in the proper position.
  40.  
  41. Install the screws to hold the channel to the roof rail.
  42.  
  43. Position the top cover listing at the index marks on the third roof bow.
  44.  
  45. Install staples 0.3 in. (8mm) apart to hold the top cover listing to the third roof bow.
  46.  
  47. Zipper the rear window into position.
  48.  
  49. Fold the rear of the top cover, tack strips and rear window down and over the third roof bow.
  50.  
  51. Position the top cover at the index marks on the rear tack strip.
  52.  
  53. Install staples 4 in. (10cm) apart to hold the top cover to the rear tack strip.
  54.  


WARNING
Cover all painted and upholstered surfaces to avoid damage while performing the following operations.

  1. Reposition the tack strips under the rear deck and quarter panels.
  2.  
  3. Place the side tack strips in position behind the quarter panels.
  4.  
  5. Install enough bolts to temporarily hold the side tack strips to the inside of the quarter panels.
  6.  
  7. Place the rear tack strip in position behind the deck panel.
  8.  
  9. Install enough bolts to temporarily hold the rear tack strip to the inner deck panel.
  10.  
  11. Close and latch the folding top.
  12.  
  13. Pull the top cover forward over the top of the windshield and hold the cover material taut.
  14.  
  15. Mark the location of the forward lower edge of the top header on the top cover material.
  16.  
  17. Release the top latches and lower the top to the midpoint.
  18.  
  19. Align the marks on the top material with the front lower edge of the top header.
  20.  
  21. Verify that the top cover will be wrinkle free and aligned side-to-side.
  22.  
  23. Install staples 0.3 in. (8mm) apart to hold the top cover to the header.
  24.  
  25. Place the top header feature strip in position under the top header.
  26.  
  27. Install staples 0.3 in. (8mm) apart to hold the feature strip to the top header.
  28.  
  29. Place the weatherstrip channel in position under the top header.
  30.  
  31. Install the screws to hold the channel to the top header.
  32.  
  33. Insert the top header weatherstrip into the header and roof rail channels.
  34.  
  35. Install the screws to hold the roof rail tension cable springs to the roof rear rail behind the quarter glass opening.
  36.  
  37. Close and latch the top windshield header.
  38.  
  39. Inspect the top cover for excessive wrinkling. If excess wrinkles are apparent, the top cover must be repositioned on the tack strips.
  40.  
  41. If the top cover is smooth, release the top header latches to allow the top cover to relax.
  42.  
  43. Remove the bolts holding the tack strips to the deck and quarter panels.
  44.  
  45. Install staples 0.3 in. (8mm) apart to hold the top cover to the rear and side tack strips.
  46.  
  47. Place the side and rear tack strips in position.
  48.  
  49. Install the bolts to hold the tack strips to the deck and quarter panels.
  50.  
  51. Insert the quarter glass weather strips into the roof rail channels.
  52.  
  53. Place the sling well into position.
  54.  
  55. Engage the snaps to hold the sling well to the rear deck and quarter panels. Verify that the drain tube is connected to the bottom of the sling well.
  56.  
  57. Install the headlining.
  58.  
  59. Close the top and latch the header to the windshield header.
  60.  

TOP LIFT ASSIST CYLINDER



Shadow/Sundance Convertible

Review the complete service procedure before starting this repair.

  1. Remove the interior trim as necessary to gain access to quarter panel-to-top frame attachment bolts and gas cylinder.
  2.  
  3. With top in up position (not latched). Loosen top frame-to-quarter panel reinforcement bolts to allow the top frame to shift rearward.
  4.  
  5. Remove the clevis pin holding gas cylinder to the top frame.
  6.  
  7. Remove the door ajar switch from the B-pillar below the door striker.
  8.  
  9. Through door ajar switch mounting hole, remove the bolt holding bottom of gas cylinder-to-quarter panel reinforcement.
  10.  
  11. Separate top lift assist cylinder from the vehicle.
  12.  

To install:
  1. Position the top lift assist cylinder in the vehicle.
  2.  
  3. Install the bottom gas cylinder-to-quarter panel reinforcement bolt.
  4.  
  5. Install the door ajar switch in the B-pillar.
  6.  
  7. Install the clevis pin to hold the top of the cylinder to the top frame.
  8.  
  9. Install the top frame-to-quarter panel reinforcement bolts.
  10.  
  11. Install the interior trim pieces.
  12.  

HYDRAULIC PUMP ASSEMBLY



LeBaron Convertible

Review the complete service procedure before starting this repair. The convertible top on this model will raise slowly or make abnormal noise if the hydraulic fluid level is low.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the sling well and floor cover from behind the rear seat.
  4.  
  5. Disconnect pump wire connector and ground connection.
  6.  
  7. Disconnect hydraulic lines from the pump assembly.
  8.  
  9. Remove the motor pump assembly from the vehicle. The rubber mounts are pressed and locked into the mounting bracket. Pull up motor assembly to remove.
  10.  

To install:
  1. Position the motor assembly in the vehicle.
  2.  
  3. Connect the hydraulic lines to the pump assembly.
  4.  
  5. Attach the pump wire connector and ground connection.
  6.  
  7. Install the sling well and floor cover behind the rear seat.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Fill the pump reservoir with ATF+3, type A, automatic transmission fluid to the bottom of the fill hole.
  12.  

 
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