Internal rollover protection beam (Defender 2007+)

Removal

1. Remove the rear seat cushions.

For more information, please refer to the chapter: Rear Outer Seat Cushion (501-10, Removal and installation) / Rear seat cushion (501-10 Seat, Removal and installation).

2. Remove the front door opening trim panels.

For more information, refer to the chapter: Front Door Opening Trim Panel (501-05 Interior trim, Removal and installation).

3. Remove the upper C-pillar trim panel.

For more information, please refer to the chapter: C-Pillar Upper Trim Panel - 4.0L, 90 (501-05, Removal and installation) / Front door frame trim panel (501-05 Interior trim, Removal and installation).

4. Remove the protruding section of the floor console.

For more information, please refer to the chapter: Floor Console Extension (501-12, Removal and installation).

5. Remove the 4 bolts securing the center section of the rollover protection bar and the seat belt buckle posts to the floor.

6. Remove the 2 Torx bolts and nuts on both sides and remove the ROPS center section assembly.

7. Remove the Torx bolt on both sides that secure the rollover protection bar to the mounting brackets on the sides of the vehicle.

8. Remove the 3 bolts on both sides and the washers securing the lower brackets of the rollover protection bar to the front of the wheel arches.

9. Remove the 2 Torx bolts on both sides and washers securing the upper ROPS support brackets to the ceiling brackets; carefully lower the assembly onto the floor.

10. Loosen the mounting bolts on both sides and remove the front seat belt reels and rear seat belts from the rollover protection bar support.



11. Using support from both sides, lift and swing the ROPS bar back to release it from the wheel arches.



12.

NOTE: Removing the ROPS bar may require the assistance of a second person.

Remove the rollover protection bar from the vehicle.

Installation

1. Position the ROPS bar with support on both sides, secure the posts to the rear corners and the front of the side panels, and adjust the position on the floor.

2. Secure the front seat belt retractors and the rear seat belts to the ROPS support posts. Tighten the bolts to 32 Nm (24 ft·lbs/ft).

3. Lift the ROPS bar assembly and secure it to the ceiling mounting brackets. Tighten the bolts to 45 Nm (33 ft·lbs/ft).

4. Secure the rollover protection bar to the wheel arches. Tighten the bolts to 45 Nm (33 ft·lbs/ft).

5. Secure the rollover protection bar to the mounting brackets on the sides of the vehicle body, tightening the bolts to 45 Nm (33 ft·lbs/ft).

6. Secure the center section of the main ROPS rod, but do not fully tighten the mounting bolts at this stage.

7. Secure the seat belt buckle posts and the ROPS floor mounting brackets to the chassis. Tighten the bolts to 32 Nm (24 ft·lbs/ft).



8. Fully tighten the center section ROPS mounting bolts to 45 Nm (33 ft·lbs/ft).

9. Install the floor console extension section.

For more information, please refer to the chapter: Floor Console Extension (501-12, Removal and installation).

10. Install the upper C-pillar trim panel.

For more information, please refer to the chapter: C-Pillar Upper Trim Panel - 4.0L, 90 (501-05, Removal and installation) / Front door frame trim panel (501-05 Interior trim, Removal and installation).

11. Install the front door opening trim panels.

For more information, refer to the chapter: Front Door Opening Trim Panel (501-05 Interior trim, Removal and installation).

12. Install the rear seat cushions.

For more information, please refer to the chapter: Rear Outer Seat Cushion (501-10, Removal and installation) / Rear seat cushion (501-10 Seat, Removal and installation).