VW Transporter T5–T6.1 Roof Panel

Installation Guide

VW T7 & New Transit Custom Roof Panel Installation Guide

CAUTION – AIRBAG CURTAIN IS FITTED TO TOP OF B PILLAR PANELS!

CAUTION – Before drilling, make sure all cables are safely moved out of the way.

1. General Notes

The new vehicles are more complicated than the older generation, so they require more work to fit. All parts are cut and ready to fit.

2. Pre-Installation Actions

• Wire in your spot lights and leave the cables hanging above the holes in the roof panel.
• Rear Alarm Sensor Modification – Remove the rear alarm sensor at the centre rear of the vehicle.

3. Vehicle Preparation

Main center spar at rear of headlining.

• There are 4 grey firtree clips holding the headlining in place. These can be prized out slightly while remaining in place or you can remove completely and refit with new.  The purpose is to allow the head lining to drop slightly so the roof panel can slide in between this and the roof spar.

Passenger Side B-Pillar

• Behind the top of the seat belt panel there is a cable clip which needs to be removed.
• Cut out the clip above the side curtain airbag to allow the cable to move and create space for the roof panel.

Driver Side B-Pillar

• Behind the top of the seat belt panel there is a cable glued to the headlining, this need removed carefully from the headlining to allow the roof panel to slide in.

Driver’s Side (Between C and D Pillars)

• There are three plastic cable clips at the rear driver’s side.
• Remove these and move the cable upwards to avoid clashing with the roof panel.

4. Filling Gaps at the B-Pillar Headlining

Four pieces are supplied:

• 2 × 12mm rear wings:
  • Suede line the roof panel first.
  • Screw these through the two pre-drilled holes from the rear of the roof panel.
  • These sit just behind the headlining panel once the roof is fitted.
• 2 × 5.5mm front wings:
  • Carpet line these pieces.
  • Offer them into position over the gap and screw them into the already fitted 12mm wings.

Important: Some vans have headlining’s positioned slightly differently during production. Always dry-fit the pieces after the rear wings are installed to confirm if any trimming is required before lining.

5. Fitting the Roof Panel in the Van – Test fit

• With a second person, offer the roof panel up to the vehicle. And slide into place under headling at front of van
• Please note: during development we found that roof spar hole positions varied from van to van, showing there is some manufacturing tolerance in the body. Because of this, the pre drilled holes in the roof may not align with the factory holes.  Offer the roof up to the van, check the alignment, and then drill to suit your vehicle — either by slightly elongating the holes or using a step drill to achieve the correct fit. Test refit roof to ensure all holes align.
• Carpet or suede line van to your requirements and refit in position
• The cables above the spotlight holes sliding door for the HALO LED now need to be connected and pushed up behind the roof panel.
• Push the panel firmly up against the roof spar and insert a clip.
• Move to the next hole and repeat until all clips are fitted.

7. Rear Alarm Sensor Modification

• Locate the previously removed rear alarm sensor.
• Split the plastic holder by undoing the clips; discard the rear half.
• Drill two screw holes into the remaining front half of the holder.
• Screw this into the HALO roof panel opening with the 2 x black screws supplied.
• Optionally spray the plastic black if the original colour is light grey.
• Make sure the cable has enough length before fitting — it may be tight and require pulling through a little extra slack.

8. Final Step

• Fit the front wings to cover the remaining gap in the headlining.
• Connect the spot lights to the cables you fitted in section 2 through the holes in the ceiling panel, test and push spots into place.