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HardDog HardCore Sport Roll Bar Install

Hardware Kit

• Shoulder Harness Guide Relocation Assemblies
  • 2 - 3/8" X 1" Grade 8 Bolts
  • 4 - 3/8" Flat Washers
  • 2 - 3/8" Lock Nuts
  • 2 - Brass Bushings
  • 2 - Plastic Trim Caps
  • 2 - Trim Cap Mounting Washers
• Upper Mounting Plate
  • 2 - 7/16"(11mm) X 2.25" Bolts
  • 2 - Spacers
  • 2 - Plastic Trim Caps
  • 2 - Trim Cap Mounting Washers
• Seat Belt Reel Plate Mounting
  • 2 - 7/16" (11mm) X 1.25" Bolts
• Foot Plate Mounting
  • 2 - Bent Back-Up Plates (Front)
  • 2 - Flat Back-Up Plates (Rear)
  • 12 - 3/8" X 1.25" Bolts
  • 12 - 3/8" Lock Nuts
  • 22 - 3/8" Flat Washers

Tools Needed

• Safety Glasses
• #2 Phillips Head Screwdriver
• Wrenches - '90 to '93
  • 16mm or 5/8"
• ‘94 & Later
  • 17mm or 11/16" 2 - 9/16"
• 10mm Drill W/ 3/8" Drill Bit (Suggest using an Angle Drill to get into the tight spots easier)
• Jack And Jack Stands
• Rotary Tool (Dremel with extension) or Aviation Snips For Cutting Package Shelf And Interior Panels
• Rotary Tool (Dremel with extension) or Half Round File For Fitting Plastic Interior Panels
• T-40 Torx Drive (Bit) for Removable Hard Top Latches (Obviously Not Everyone Will Need This One)

Instructions

• Put the Convertible Top down or take off your Hard Top.
• Take out your Seats and the Center Console.
  • This isn't a required step, but it makes life a lot easier when you're trying to do the install.
• Remove the Trim Panels covering the Seat Belt Towers.
  • First remove the metal cap at the top of the panel just behind the door. This is held in place by a threaded fastener that is used to attach the top boot (10mm) and a Phillips head screw on the pre ‘99 cars. The M2 version is similar but an extra rubber molding has been added that is held in place by a plastic insert inside the top of the door jamb and another under the lip of the body just behind the door. Remove the weather-stripping that runs along the front edge of the trim panel at the rear of the door opening. (you might find it necessary to loosen the 4 Phillips head screws in the scuff plate that runs along the bottom of the door sill on some early models) Remove the plastic cover from the shoulder harness guide (it just snaps off), loosen the bolts and remove the bolt and spacers from the guide. On the ‘94-’97 models Remove the cockpit brace end covers (they also snap), loosen the bolts and remove the cockpit brace. There is a small plastic clip at the rear of the trim panel just behind the hole the shoulder harness guide bolt goes through. Remove the clip by pulling it toward the rear of the car. Remove the rectangular seat belt trim ring at the front of the panel and the 2 fasteners in each trim panel located on the inside just above the package tray, one is a kind of plastic rivet that is loosened by lifting the center portion and pulling it free, the other is another one of those fancy boot cover snaps with the 10mm head. If you have a ‘99 with the wind blocker remove the screws and lift the wind blocker out. The trim panel can now be removed by pulling it toward the center of the car, there’s a couple of snap type fasteners down low just behind the door that you will need to pop loose as the panel is pulled free.
• Put the Convertible Top up.
  • Completely remove the carpet from the fuel tank cover (the silver cover that makes up the front part of the package shelf). A claw hammer is a good tool for removing the plastic carpet fasteners, and also on ‘99+ there's two black "bump stops" for the convertible top to rest on that need to be removed as well. Lower the top. (Pre ‘99 leave the window zipped in, be careful not to crease the window) Some sort of cover for the window is not a bad idea. Remove the large silver metal fuel tank cover that makes up the front part of the package shelf by removing the several bolts w/ 10mm heads that hold it in place and releasing any wire loom fasteners. Lift the cover up and out of the car. On the ‘94-97 models there’s a computer mounted behind the passenger seat, the outer mounting bracket will need to be modified and the upper mounting stud removed to allow clearance for the roll bar mounting plate. You will need to remove the spare tire and the metal panel at the front of the trunk on the driver’s side (the one with the jack handle attached) if you are working on a pre ‘99. While it’s not absolutely necessary to do so, I find it helpful to remove the front trunk panels in the M2, they are held in by several of those nifty little plastic rivet fasteners.
• Remove the Lower Seat Belt Reel Bolts (16mm pre ‘94/17mm ‘94 and later) and Spacers.
  • Also remove seat belt reel alignment screw at the top of the mounting bracket (small screw w/10mm head).
• Set the Bar in the Car - Be CAREFUL
  • The rear brace foot plates will just fit under the front edge of the package tray, work the rear braces past the several wiring harnesses in this area being careful not to mess up any of the wiring. The horizontal mounting plates half way up the bar should fit over the top of the seat belt tower and align with the bolt hole that held the shoulder harness guide. The lower mounting points align (hopefully) with the lower seat belt reel bolt holes. The roll bar plates fit against the seat belt reels which stay in their original location but do not use the original spacers. Once the Sport Bar and the seat belt reels are in position start, but do not completely, tighten the seat belt reel mounting plate bolts from the hardware kit, make sure that your seat belts are on the inside of the roll bar. Using the bolts and spacers from the hardware kit, install the upper mounting bolts through the upper mounting plate with the spacer under the plate in place of the original shoulder harness guide bolt and spacers. If you have a problem with alignment partially tighten the seat belt reel bolts and pull the rear braces toward the rear by reaching through from the trunk. Be sure the trim cap mounting washers are under the bolt heads. The shoulder harness guide is NOT installed at this point, DO NOT install the guide under the mounting bolt. Attach the seat guide to the bar through the smaller hole in the upper mounting plate using the bolts, washers and bushings supplied in the hardware kit. Be careful, don’t drop any hardware down in the seat belt reel. Tighten to 20 ft-lbs. Once you have the seat belt reel and the upper mounting plate bolts started and no wires are pinched tighten them to 50 ft-lbs.
• Jack up the Rear of the Car and Support with Sturdy Jack Stands.
  • Remove the wheels and plastic splash panels from the front of the inner fenders. (pre 99 - 4 bolts with 10mm heads / M2 - 4 plastic fasteners with Phillips heads)
• Get the Drill. (Safety Glasses optional but suggested)
  • Locate the position for the rear back-up plates by drilling the first hole down from the top. Once you get the first hole drilled, bolt the back-up plate in place, the others can be done from under the car using the back-up plate as a template (Although if you're using an angle drill it would be easier from the top down). The nuts closest to the frame rail do not use washers because of their proximity to the rail. On the M2, part of the evaporative emission system is located in the wheel well on the passenger side. A snap fastener holds a small filter just behind the battery cable grommet. Loosen for the rollbar installation, and use a zip tie to tie it to something nearby after the bolts are tightened on that side. The front plates are easy, just drill from the front and bolt the back-up plates in place using washers under all nuts and bolts. It's not unheard of that one of the front plates on both M1's and M2's don't line up correctly, so have a vise or something to help you bend it if nessecary. Tighten to 35-40 ft-lbs. Spraying the back-up plates with undercoating after the fasteners are tight is a good idea. Install the splash panels, rear tires, trunk panels and spare.
• Check Convertible Top clearance.
  • It may be necessary to adjust the top frame to allow clearance when the top is lowered and raised especially with the covered bars. Raise the top slowly checking clearance as the hinge points come up past the bar. If the hinge points rub loosen the (3) bolts with 12mm heads behind either door jamb that hold the top frame. Pull the frame as far to the rear as possible, you might need to lift the top slightly to allow more movement. tighten the bolts while holding pressure on the top and recheck clearance.
• Trim the Fuel Tank Cover. (Easily done with a Dremel or Rotary Tool)
  • On the pre 99’s it’s a small notch at the rear corners. The M2 requires a notch on either side, use the bolt holes for reference points. Bend the rear corners to clear the bar until the panel is in place then flatten into place. Install the fuel tank cover, raise the top put the carpet back in place and trim around the roll bar.
• Cut Quarter Trim Panels. (Also easily done with a Dremel or Rotary Tool)
  • In order to reinstall the trim panels they have to be cut into two pieces. It’s not really hard, it just takes some time to do it right. The pictures to the right should help some. You just need to cut the trim panels to fit up right to the rollbar. Its also better to take smaller pieces off and work at it a few times to get it right than to try and get it all at once. You'll have to cut a semi-circular area around the top of the panel for it to fit up against the bar. You'll also have to elongate the so it will also fit up against the back of the bar. And finally you'll have to cut a notch, like the panel in the pictures, so it can fit up against the front plate of the rollbar. (I would suggest trying to contract Mike out to do your panels as he did an awesome job on his in these pics)
• Reinstall the Remaining Parts.
  • You'll need to reinstall your center console and your seats, especially if you want to take it for a spin right away(or you could be like Mike and try driving without your seats!). In M2's, you can reinstall the windblocker, but the ends of the top flap will not clear the bar during the transition from up to down. You can trim the ends of the top flap, leave it in the down or up position, or drill new holes in the front and attach it with sheetmetal screws to relocate it to the front.
• Leftovers.
  • You will have some leftovers. Seat belt reel spacers, bolts and screws, shoulder harness guide trim, bolts and spacers. Keep them for a rainy day.