Members Home > Articles > How To Install The Newer Factory Roll Bar (Sport Bar) In Older Wranglers

How To Install The Newer Factory Roll Bar (Sport Bar) In Older Wranglers

I'm writing this from memory since my 93 YJ has the full factory sport bar. Notice I say "sport bar". Jeep doesn't call it a rollbar anymore and you should consider it super strong in the event of a rollover. The best thing you can do is either have the factory bar strengthened by adding supports or buying a full cage. But most Jeepers don't do either of these so at least it's good to have the more modern full version instead of the slanted version that appear on YJ's from 87-92. The newer sport bar also will give you the option of adding shoulder belts in the rear to replace the lap belts. We often have people riding in the back so on our old 88 YJ we felt it was important to swap in the newer sport bar. Also, it made our 88 instantly look newer and bigger (the old slanted sport bars make Jeeps look smaller in my opinion). Fortunately the bolt locations are the same for both so in general all you need to do is go to a salvage yard or find someone selling their sport bar, unbolt yours and then install the new one. There are two main difficulties in accomplishing this, however.

First, the torx bolts securing the sport cage to the windshield were robot-installed and torqued very tight. An impact wrench might help you remove these. I've done it by hand and although most of the 6 bolts came out after a while, a couple become a problem when I eventually stripped the torx heads. The only solution at that point was for me to drill into the bolts (very hard steel) and then use bolt extraction bits (about $25 at hardware stores) to try and remove the bolts. This took hours and was a TOTAL pain. you must not ruin the threads of the bolt holes, either, since you'll need to bolt on the new bars. What I would do differently next time is to leave the bars that connect to the windshield in tact. They bolt to the rear section so you could remove the rear bolts and take off the rear section of the sport bar and replace it with the new one. That should work and I bet it would be easier.

Second, the new rear bars won't perfectly line up so you'll need some help carefully "encouraging" them enough so you can get the new bolts in. It's not that difficult but it's best to have some help.

Parts:

93 or newer factory sport bar

Tools Used:

Rachet set
Torx socket set
Drill and bolt extraction bits (for when you strip the torx heads)

Sorry, no pictures. If I find some before and after pics of my old Jeep, I'll put them up. I got a good camera only after I sold that Jeep.