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Convertible Top: Other Ford Thunderbird XI

Sun Roof/t-Top/convertible Top 71 illustrations ~2816 words

Removable Top

The removable top consists of the following components

  1. rear window glass
  2. side glass/bezel
  3. removable top latches
  4. weather seals
  5. weather seal retainers
  6. headliner

To install a new removable top rear window glass, refer to GLASS, FRAMES AND MECHANISMS . To install a new removable top latch assembly, refer to HANDLES, LOCKS, LATCHES AND ENTRY SYSTEMS .

Stay Pad

The stay pad is attached to the bows and is repaired as a component. The number two bow is spring-loaded.

Only one new stay pad at a time should be installed.

Hydraulic System

The convertible top hydraulic system is comprised of the lift cylinders, the motor, the connecting hydraulic lines and a convertible top switch. The hydraulic system, except for the convertible top switch, is removed as an assembly, but the components may be repaired separately.

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Scheme 22: Special Tool(s)
Scheme 22: Special Tool(s)

Material

ItemSpecification
Threadlock and Sealer E0AZ-19554-AAWSK-M2G351-A5 (type II)

Material Specification - Linkage Adjustment

Note. The following adjustments are listed in the order of fine to coarse adjustment. Make the adjustments on the side that coordinates with the overshoot condition.

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Scheme 23: The Convertible Top Dowel Pins Fall Forward Of The Receiver Cups (Overshoot)
Scheme 23: The Convertible Top Dowel Pins Fall Forward Of The Receiver Cups (Overshoot)
  1. Fully raise the convertible top until the hydraulic pump motor stalls for three seconds.
  2. Examine the position of the dowel pins relative to the receiver cups. Note the side that has the condition (right or left).
  3. Adjust the B-hinge set screw by turning in the screw about one-half turn (fine adjustment).
  4. Adjust the upstop at the main pivot bracket approximately 14 mm (0.56 in) (0.6 in) from the base.
  5. Adjust the position of the number one bow to the side arm (move the number one bow rearward) as follows: Lower the convertible top about one-quarter of the way down. Locate the two bolts under the cloth material that fasten the number one bow to the side arm. Loosen the bolts and slide the number one bow rearward and tighten the bolts.

Note. The following adjustments are listed in the order of fine to coarse adjustment. Make the adjustments on the side that coordinates with the undershoot condition.

Scheme 24

Scheme 24: The Convertible Top Dowel Pins Fall Rearward Of The Receiver Cups (Undershoot)
Scheme 24: The Convertible Top Dowel Pins Fall Rearward Of The Receiver Cups (Undershoot)
  1. Fully raise the convertible top until the hydraulic pump motor stalls for three seconds.
  2. Examine the position of the dowel pins relative to the receiver cups. Note the side that has the condition (right or left).
  3. Adjust the B-hinge set screw by turning out the screw about one-half turn (fine adjustment).
  4. Adjust the position of the number one bow to the side arm (move the number one bow forward) as follows: Lower the top about one-quarter of the way down. Locate the two bolts under the cloth material that fasten the number one bow to the side arm. Loosen the bolts and slide the number one bow forward and tighten the bolts.

Note. Pull down effort is defined as the effort necessary to engage the J-hooks into the receivers after running the top motor to the full up position and stalling the motor for three seconds.

Note. Latch effort is defined as the effort necessary to fully close the center latch handle after the J-hooks are engaged into the receivers.

Note. If the convertible top has been in the stowed/down position for a long period of time, or if the removable top has been on for a long period of time, the first time to latch the convertible top may be difficult, occasionally requiring two people. Often, keeping the top latched will relieve effort. It is recommended that the convertible top remains latched over night and during long periods of non vehicle usage.

Note. A new convertible top installed by the dealer will typically experience high-pull down effort.

  1. Allow the top to remain latched continuously for 24-48 hours. Allow the top to receive direct sunlight if the external temperature is above 10°C(50°F).
  2. Latch the top and apply heat to the outer surface of the cloth (using a paint booth or heat lamps).

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Scheme 25: Convertible Top Does Not "Lock-Up" When Raised
Scheme 25: Convertible Top Does Not "Lock-Up" When Raised
  1. Cycle the convertible top from down to up. View the condition of the B-hinge joint. If the joint does not come together or lock at end of travel (full up), adjustment is necessary.
  2. With the folding top in the down/folded condition, access the lower attachment bolt of the balance link to the main pivot bracket. Loosen the joint and adjust the balance link down approximately 1-2 mm (0.04-0.08 in).
  3. Retest for condition. If condition still exists, proceed to the next step.
  4. Raise the top and access the main control link adjustment from inside the vehicle by slightly lifting the headliner.
  5. Loosen the bolts in the main control link adjustment bracket and move the link forward 1mm (0.04 in).
  6. Retest for condition. If condition still exists, repeat the adjustment procedure.

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Scheme 26: Convertible Top No. 1 Bow Is Not Flush To The Header Chrome Molding
Scheme 26: Convertible Top No. 1 Bow Is Not Flush To The Header Chrome Molding
  1. Remove the J-hook set screw.
  2. Turn the J-hook in (clockwise) by one turn.
  3. Install the set screw. Add blue threadlock and sealer to the set screw.

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Scheme 27: Removal and Installation
Scheme 27: Removal and Installation

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Scheme 38
  1. With the convertible top closed and unlatched, detach the well sling interior trim cover.
  2. Remove the 15 convertible top tacking strip nuts.
  3. Remove the two body side panel support brackets.
  4. Disconnect the rear window defrost grid electrical connector locator from the body.
  5. Disconnect the rear window defrost grid electrical connector and route the wire out through the hole in the well sling interior trim cover.
  6. Remove the ground bolt for the rear window defrost grid.
  7. Route the rear window defrost grid ground wire out through the hole in the well sling interior trim cover.
  8. Cycle the convertible top down into the top well.
  9. Remove the screw from the convertible top material at the sail panel brackets.
  10. Cycle the convertible top upwards towards the closed position.
  11. Lift the rear of the convertible top upwards.
  12. Position the two lift cylinders aside. Remove the two bolts. Remove the two nuts.
  13. Manually cycle the convertible top down into the top well.
  14. Remove the four bolts for the two hardtop locator brackets.
  15. Position the front door weatherstrips aside.
  16. Remove the hardtop locator bracket shroud covers.
  17. Remove the four bolts for the two hardtop locator brackets.
  18. Disconnect the hardtop sense switch wiring connector and remove the two hardtop locator brackets.
  19. Remove the convertible top assembly. Loosen the lower bolts. Remove the upper bolts.
  20. To install, reverse the removal procedure.

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Scheme 39: Removal
Scheme 39: Removal

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Scheme 44
  1. With the convertible top closed and unlatched, detach the well sling interior trim cover and position aside.
  2. Disconnect the rear window defrost grid electrical connector locator from the body.
  3. Disconnect the rear window defrost grid electrical connector and route the wire out through the hole in the well sling interior trim cover.
  4. Remove the ground bolt for the rear window defrost grid.
  5. Route the rear window defrost grid ground wire out through the hole in the well sling interior trim cover.
  6. Position the well sling interior trim cover aside.
  7. Remove the two rear headliner screws from the rear tacking strip and position the headliner aside.
  8. Mark the convertible top material as necessary using a grease pencil.
  9. Remove the 15 convertible top tacking strip nuts.
  10. Remove the two body side panel support brackets.
  11. Position the three convertible top tacking strips aside.
  12. Remove enough staples to free the convertible top cover from the three tacking strips.
  13. Mark the winter seal at the top, bottom and the forward edge of the three tacking strips using a grease pencil.
  14. Lift the rear cover assembly over the convertible top exposing the top of the rear window glass assembly shroud.
  15. Mark the center of the rear window glass assembly shroud to the number four bow using a grease pencil.
  16. Remove all of the staples along the number four bow from the top material listing, insulator pad, headliner listing, and corner Velcro(R) pieces.
  17. Remove the corner Velcro(R) pieces from the number four bow.
  18. Remove the rear window glass assembly and set on a workbench.
  19. Remove the staples from the lower edge of the rear window glass assembly shroud and the three tacking strips.

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Scheme 45: Installation
Scheme 45: Installation

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  1. Overlay the new rear window glass assembly over the old rear window glass assembly and transpose the markings using a grease pencil.
  2. Staple the three tacking strips to the new rear window glass assembly shroud.
  3. Position the new rear window glass assembly into the vehicle
  4. Center the V-notch on the rear window glass assembly to the center mark on the top of the number four bow.
  5. Align the rear window glass assembly shroud to the top groove of the number four bow and staple the entire length.
  6. Install new corner Velcro(R) pieces on the number four bow.
  7. Align the headliner listing, insulator pad, and the top material listing, to the centerline mark and staple the entire length along the number four bow.
  8. Verify correct fit of the three tacking strips
  9. Align the top edge of the quarter tacking strips to the grease pencil marks on the convertible top cover and rear window glass assembly shroud.
  10. Verify correct fit of the rear window glass assembly to the convertible top.
  11. Install the three tacking strips over the body studs.
  12. Install the two body side panel support brackets.
  13. Tighten the 15 convertible top tacking strip nuts.
  14. Position the headliner and install the two screws to the rear tacking strip.
  15. Route the rear window defrost grid ground wire through the hole in the well sling interior trim cover.
  16. Install the rear defrost grid ground bolt.
  17. Route the rear window defrost grid wire through the hole in the well sling interior trim cover.
  18. Connect the rear defrost grid electrical connector and attach the locator to the body.
  19. Install the well sling interior trim cover.

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Scheme 53: Removal
Scheme 53: Removal

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  1. Cycle the convertible top down into the top well.
  2. Remove the screw from the convertible top material at the sail panel brackets.
  3. Mark the convertible top material to the front edge of the convertible top header using a grease pencil.
  4. Remove the 13 screws and the seal compression panel from the convertible top header.
  5. Remove the staples from the header and loosen the convertible top material from the header.
  6. Remove the two front weather seal screws.
  7. Remove the two front weather seals.
  8. Mark the two front weather seal retainers to the top assembly using a grease pencil.
  9. Remove the two front weather seal retainers. Remove the screws.
  10. Remove both front headliner screws from the convertible top assembly.
  11. Cycle the convertible top upwards toward the closed position.
  12. Remove the two rear weather seals.
  13. Remove the two rear weather seal retainers. Remove the screws.
  14. Cycle the convertible top to the halfway open position.
  15. Disconnect the two top assist straps from the convertible top frame. Remove the two rivets.
  16. Remove the two folding top tension cables from the convertible top assembly. Remove the two rivets.
  17. With the convertible top closed and unlatched, detach the well sling interior trim cover.
  18. Disconnect the rear window defrost grid electrical connector from the body.
  19. Disconnect the rear window defrost grid electrical connector and route the wire out through the hole in the well sling interior trim cover.
  20. Remove the ground bolt for the rear window defrost grid.
  21. Route the rear window defrost grid ground wire out through the hole in the well sling interior trim cover.
  22. Position the well sling interior trim cover aside.
  23. Remove the rear headliner screws from the rear tacking strip and position the headliner aside.
  24. Mark the convertible top material as necessary using a grease pencil.
  25. Remove the 15 convertible top tacking strip nuts.
  26. Remove the two body side panel support brackets.
  27. Position the three convertible top tacking strips aside.
  28. Remove enough staples to free the top cover from the three tacking strips.
  29. Mark the winter seal at the top, bottom and the forward edge of the rear tacking strip using a grease pencil.
  30. Lift the rear cover assembly over the convertible top exposing the top of the rear window glass assembly shroud.
  31. Mark the center of the rear window glass assembly shroud to the number four bow using a grease pencil.
  32. Remove all of the staples along the number four bow from the top material listing, insulator pad, headliner listing, and corner Velcro(R) pieces.
  33. Remove the convertible top material from the vehicle and place on a workbench.

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Scheme 69: Installation
Scheme 69: Installation

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  1. Transfer the markings from the old convertible top material to the new convertible top material and mark the hole for the sail panel bracket and screw on each side using a grease pencil.
  2. Position the new convertible top material to the vehicle.
  3. Attach the top material listing to the center mark on the number four bow.
  4. Install the two folding top tension cables through the top packets. Install the two rivets.
  5. Install the two top assist straps. Install the two rivets.
  6. Cycle the convertible top to the half open position.
  7. Align the grease pencil markings at the front of the convertible top material to the top header.
  8. Apply Weather Strip Adhesive part number E8AZ-19552-A, meeting Ford specification ESB-M2G14-A, to both the front of the convertible top material and the top header frame.
  9. Attach the convertible top material to the top header frame.
  10. Cycle the convertible top closed to put tension on the top.
  11. Align the headliner listing, insulator pad, and the top material listing, to the centerline mark and staple the entire length along the number four bow.
  12. Verify correct fit of the tacking strips.
  13. Staple the convertible top material to the tacking strips.
  14. Install the tacking strips over the body studs.
  15. Install the two body side panel support brackets.
  16. Tighten the 15 tacking strip nuts.
  17. Install the two rear headliner screws to the rear tacking strip.
  18. Apply Weather Strip Adhesive part number E8AZ-19552-A, meeting Ford specification ESB-M2G14-A, and attach the rear rail cloth retainer on each side.
  19. Install the two rear weather seal retainers. Install the screws.
  20. Install the two rear weather seals.
  21. Cycle the convertible top down into the top well.
  22. Staple the front of the convertible top material to the top header.
  23. Install the compression panel. Install the screws.
  24. Install the two front weather seal retainers. Install the screws.
  25. Install the two front weather seals.
  26. Install the two front weather seal screws.
  27. Install the screw to the convertible top material at the sail panel brackets.
  28. Position the headliner to the top assembly and install the two front screws.
  29. Cycle the top closed to put tension on the top.
  30. Verify correct fit of the convertible top assembly and adjust as necessary.
  31. Route the rear window defrost grid ground wire through the hole in the well sling interior trim cover.
  32. Install the rear window defrost grid ground bolt.
  33. Route the rear window defrost grid wire through the hole in the well sling interior trim cover.
  34. Connect the rear window defrost grid electrical connector and attach the locator to the body.
  35. Install the interior well sling trim cover.

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Scheme 86: Removal
Scheme 86: Removal

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Scheme 87
  1. Remove the convertible top material. For additional information, refer to «CONVERTIBLE TOP MATERIAL»(ref-204644-S09646204942005111300000) .
  2. Remove the corner Velcro(R) piece from the number four bow.
  3. Remove the corner staples from the convertible top rear window glass shroud until the stay pad is exposed.
  4. Mark the old stay pad staple locations and transfer the marks to the new stay pad using a grease pencil.
  5. Remove the stay pad staples from all of the top bows.
  6. Remove the stay pad. Remove the rivets.

Scheme 88

Scheme 88: Installation
Scheme 88: Installation
  1. Position the new stay pad onto the convertible top assembly using the grease pencil markings.
  2. Rivet the front of the stay pad to the front header assembly.
  3. Rivet the stay pad tab to the number four bow.
  4. Cycle the convertible top to relieve tension from the stay pad.
  5. Staple the stay pad to the number four bow.
  6. Staple the convertible top rear window glass assembly shroud to the number four top bow.
  7. Install a new corner Velcro(R) piece to the number four bow.
  8. Cycle the convertible top closed.
  9. Latch down and tension the top, position the number two and number three bows to the center of the marks on the stay pad.
  10. Staple the stay pad to the number two and number three bows.
  11. Staple the stay pad to the number three bow.
  12. Install the convertible top material. For additional information, refer to «CONVERTIBLE TOP MATERIAL»(ref-204644-S09646204942005111300000) .

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Scheme 89: Removal and Installation
Scheme 89: Removal and Installation

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  1. Remove the lower instrument panel center finish panel.
  2. Remove the bolts and the instrument panel center finish panel.
  3. Disconnect the convertible top control switch electrical connector.
  4. Remove the convertible top control switch. Release the locking tabs.
  5. To install, reverse the removal procedure.

More articles — Convertible Top