Manuel de montage - Gullwing TD4
| Réf. | Désignation | Qté |
|---|---|---|
| 1 | Panneau aluminium gullwing | 1 |
| 2 | Charnières | 2 |
| 3 | Vérins à gaz | 2 |
| 4 | Supports vérin avec rotule intérieure | 2 |
| 5 | Supports vérin avec rotule extérieure | 2 |
| 6 | Joint d'étanchéité périphérique | 1 |
| 7 | Poussoirs de verrouillage à verrou et clés | 2 |
| 8 | Vis FHC M5x20 mm — Inox A2 noire | 4 |
| 9 | Vis FHC M5x16 mm — Inox A2 | 4 |
| 10 | Écrous frein M5 — Inox A2 | 4 |
| 11 | Rondelles M5 — Inox A2 | 4 |
| 12 | Caches écrous M5 — Plastique noir | 4 |
| 13 | Vis H M4x12 mm — Inox A2 | 4 |
| 14 | Écrous frein M4 — Inox A2 | 8 |
| 15 | Vis FHC M4x14 mm — Inox A2 | 4 |
| 16 | Rondelles M4 — Inox A2 | 4 |
| 17 | Caches écrous M4 — Plastique noir | 8 |
17 références — 60 pièces au total.
4. Required tools
Tools not supplied, to be prepared before starting assembly:
- Set of open-end / ratchet wrenches: 7 mm and 8 mm sizes
- Hex keys
- Drill driver
- Metal drill bits: Ø 4.5 mm and Ø 5.5 mm
- Marking pencil
- Window breaker
- Microfiber cloths and cleaning product
- Adjustment shims for window alignment
- Silicone grease
5. Difficulty level and estimated time
Intermediate Difficulty — Two people recommended
Estimated Time — 2 to 3 hours
Skills required — Basic automotive DIY, no advanced electrical skills required
6. Vehicle preparation
6.1 Area preparation
- Remove the interior trims around the window.
- Prepare the area by protecting the bodywork.
Body protection before intervention: A plastic tarp and painting-type masking tape are sufficient. This is also the ideal time to refurbish the window pillar's paint.
⚠ Two possible methods
From here, two options are available: quick disassembly (breaking the window in its frame) or complete dismantling of the window pillar (very tedious).
Only the first option is described below. When performed correctly, it does not damage the vehicle, saves many hours of disassembly/reassembly, and avoids having to redo the pillar's waterproofing.
6.2 Removal of the original window
- If your window does not have a film, it is advisable to tape one side to prevent the scattering of glass fragments.
- Place cardboard around the window to collect as many glass fragments as possible.
- Break the exterior window.
4. Unscrew the upper and lower screws holding the window's central support/pillar. If you current layout does not allow access to the screw's head, You can drill through them from the second window channel/groove. This may result in the second pane of glass, which is expected.
5. Remove the window's central support/pillar.
6. If not already done, break the inner pane of glass.
7. Remove the seals and all glass fragments that may have lodged in the window frame.
8. Clean the grooves of the frames that will receive the gullwing window seal.
7. Assembly Steps
Perform the steps below in the order indicated. Do not definitively tighten the screws before checking the complete alignment of the frame (step 7.2).
7.1 Seal Installation
- Check that no debris remains in the seal's location (outer groove).
- Lightly grease the seal and the groove to facilitate insertion.
- For the next step, keep the upper part of the seal out of its housing to mark and drill the hinge holes.
- Without using a sharp tool, push the seal into its housing, respecting its orientation (small radii at the top, large radii at the bottom). Installation can be difficult, but it will prevent the assembly from coming off unexpectedly.
- If necessary, reposition the corners of the seal to their final position.
7.2 Dry Fitting the Frame
- Mount the "window" part of the hinge onto the window. Screws:
• 4 × black FHC M5×20 stainless steel screws
• 4 × M5 stainless steel washers
• 4 × M5 lock nuts
2. Attach the "frame" part of the hinge to the "window" part, without using the locking clip, to allow for reassembly.
3. Position and manually hold the aluminum gullwing window in the opening, without fixing it.
4. Visually check the peripheral clearance: it must be even all around.
5. Mark the drilling positions of the hinges on the window frame. It is recommended to cover the frame with painter's tape to avoid marking the frame directly.
6. Reposition the frame blank and check that the markings made correspond.
7. Punch, then drill to Ø 5.5 mm the four screw locations.
8. Clean the drill holes and remove any swarf or burrs.
7.3 Gullwing window mounting
1. Mount the hinge base on the frame, in the pre-drilled locations.
Fasteners:
• 4 × M5×10 FHC stainless steel screws
• 4 × M5 locknuts
2. Position the window and assemble the hinges without locking them.
3. Ensure the window is properly centered in the frame; if necessary, adjust the position of the hinge bases.
4. Once satisfied with the result, fully tighten the screws and place the hinge locking clips in their designated slots
5. Cut the gaskets cleanly at the hinge screw locations, then finish inserting the gasket into the groove along the entire top of the frame.
6. At this stage, the window should be able to be held manually in its final closed position; all that remains is to install the hinges.
7.4 Mounting the gas springs
- Remove the safety clips from the ball joints.
2. Place the ball-joint hubs onto the inner ball-joints of the ram supports, then reinsert the safety pins.
3. Mount the two strut brackets with the ball joint facing inward on the aluminum plate. The ball joint should point outward from the plate.
Hardware:
• 4 × FHC M4×14 stainless steel screws
• 4 × FHC M4 screw covers with caps
• 4 × M4 lock nuts
4. Hold the window in the fully open position and mark the frame at the M4 drilling locations for the cylinder brackets.
5. Center punch and drill Ø 4.5 mm at the marked locations.
⚠ Warning: Protect or remove the seals at this location to prevent slipping during drilling.
6. Screw the cylinders onto the ball joints of the previously mounted brackets.
⚠ Warning: The cylinders must be mounted with the wider diameter on the window side and the rod on the frame side, to ensure lubrication of the rod by gravity.
7. Screw the two remaining cylinder brackets onto the other end of the cylinders (rod side).
8. Screw these two brackets into the pre-drilled window frame.
Hardware:
• 4 × H M4×14 stainless steel screws
• 4 × M4 lock nuts
• 4 × M4 washers
9. Check the proper functioning of the hinges and adjust the pressure of the closing latches to ensure the seal's tightness around the entire frame. A firm push is required to open the compression latches!
10. Installation complete.
⚠ Note: As the rubber seal is new, it is normal to observe small gaps in certain parts of the seal. Allow it time to settle into its final shape. After some time, remember to retighten the compression lock screws to ensure adequate sealing.
8. Settings and Adjustments
- Window alignment: Uniform peripheral clearance, visually checked around the entire perimeter.
- Locking system adjustment: The closure must be positive and firm, with no residual play.
9. Final Checks
- Perform about ten full opening/closing cycles to validate proper operation.
- Visually check for any water infiltration inside the vehicle.
- Check the tightening of all screws.
- Plan a second tightening check after a break-in period of approximately 500 km.
10. Recommended Maintenance
- Clean the seals every 3 months with a soft cloth and a non-aggressive product.
- Grease the hinges and struts every 6 months, or before each season of intensive use.
- Recheck the tightening of the screws after the break-in period, then once a year.
- Inspect the condition of the seals before winter and before summer (cracks, hardening).
- In case of frequent off-road use, check for any play in the hinges after each intensive outing.
Kit designed and distributed by Side Seeker — Expedition Gear.
Manual version 0.1 — August 10th, 2026. Document subject to change.