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BODY (Continued)
BODY
23 - 5
CODE
FAMILY NAME
COMMON TRADE NAME
TYPICAL APPLICATION
PC/ABS
PC/ABS ALLOY
PPO
POLYPHENYLENE OXIDE
POLYPHENYLENE/ POLYAMID FIBERGLASS REINFORCED PLASTIC POLYSTYRENE
RESIN TRANSFER MOLDING COMPOUND SHEET MOLDED COMPOUND TRANSFER MOLDING COMPOUND UNSATURATED POLYESTER (THERMOSETTING)
ETHER/ESTER BLOCKED CO-POLYMER EEBC/POLYBUTYLENE TEREPTHALATE ETHYLENE MODIFIED POLYPROPYLENE ETHYLENE/ PROPROPYLENE DIENE MONOMER ETHYLENE/ PROPROPYLENE CO- POLYMER FOAM POLYURETHANE POLYETHYLENE
POLYPROPYLENE (BLENDS) PP/EPDM ALLOY POLYURETHANE PUR/PC ALLOY POLYVINYL CHLORIDE
PPO/PA
PR/FV
PS
RTM
SMC
TMC
UP
EEBC
EEBC/PBTP
EMPP
EPDM
EPM
MPU PE
PP
PP/EPDM PUR PUR/PC PVC
RIM
RRIM
GERMAX, BAY BLENDS, PULSE AZDEL, HOSTALEN, MARLEX, PRFAX, NORYL, GTX, PPO PPO/PA, GTX 910
DOORS, INSTRUMENT PANELS INTERIOR TRIM, DOOR PANELS, SPLASH SHIELDS, STEERING COLUMN SHROUD FENDERS, QUARTER PANELS
FIBERGLASS, FV, PR/FV
BODY PANELS
LUSTREX, STYRON, PS
RTM
SMC
TMC
SMC, BMC, TMC, ZMC, IMC, XSMC, UP
EEBC
DOOR PANELS, DASH PANELS BODY PANELS
BODY PANELS
GRILLES
GRILLE OPENING PANEL, LIFTGATES, FLARESIDE FENDERS, FENDER EXTENSIONS BUMPERS
EEBC, PBTP, BEXLOY
BUMPER, ROCKER PANELS
EMPP
BUMPER COVERS
EPDM, NORDEL, VISTALON
BUMPERS
EPM
MPU ALATHON, DYLAN, LUPOLEN, MARLEX NORYL, AZDEL, MARLOX, DYLON, PRAVEX PP/EPDM COLONELS, PUR, PU TEXIN APEX, GEON, VINYLITE
FENDERS
SPOILERS
INNER FENDER, SPOILERS, KICK PANELS SPOILERS, GRILLES FASCIAS, BUMPERS BUMPERS BODY MOLDINGS, WIRE INSULATION, STEERING WHEELS FRONT FASCIAS, MODULAR WINDOWS FASCIAS, BODY PANELS, BODY TRIMS
REACTION INJECTED MOLDED POLYURETHANE REINFORCED REACTION INJECTED MOLDED
RIM, BAYFLEX
PUR, RRIM
BODY
23 - 6
BODY (Continued)DR
CODE
FAMILY NAME
COMMON TRADE NAME
TYPICAL APPLICATION
TPE
TPO
TPP
TPU
THERMO POLYETHYLENE
TPE, HYTREL, BEXLOY-V
THERMOPOLYOLEFIN
THERMO- POLYPROPYLENE THERMOPOLYURETHANE, POLYESTER
POLYTROPE, RENFLEX, SANTOPRENE, VISAFLEX, ETA, APEX, TPO, SHIELDS, CLADDINGS TPP
TPU, HYTREL, TEXIN, ESTANE
FASCIAS, BUMPERS, CLADDINGS BUMPERS, END CAPS, TELCAR, RUBBER, STRIPS, SIGHT, INTERIOR B POST
BUMPERS
BUMPERS, BODY SIDE, MOLDINGS, FENDERS, FASCIAS
PANEL SECTIONING
If it is required to section a large panel for a plas- tic repair, it will be necessary to reinforce the panel (Fig. 1). To bond two plastic panels together, a rein- forcement must overlap both panels. The panels must be “V’d” at a 20 degree angle. The area to be reinforced should be washed, then sanded. Be sure to wipe off any excess soap and water when finished. Lightly sand or abrade the plastic with an abrasive pad or sandpaper. Blow off any dust with compressed air or wipe with a clean dry rag.
to cure, rough sand the seam and apply the final adhesive filler to the area being repaired. Smooth the filler with a spreader, wooden tongue depressor, or squeegee. For fine texturing, a small amount of water can be applied to the filler surface while smoothing. The cured filler can be sanded as neces- sary and, as a final step, cleanup can be done with soapy water. Wipe the surface clean with a dry cloth allowing time for the panel to dry before moving on with the repair.
PANEL REINFORCEMENT
Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing. Reinforcements can be made with several applications of glass cloth saturated with structural adhesive. Semi-rigid or flexible repair materials should be used for semi-rigid or flexible backing rein- forcement (Fig. 2) and (Fig. 3). Open meshed fiber- glass dry wall tape can be used to form a reinforcement. The dry wall tape allows the resin to penetrate through and make a good bond between the panel and the adhesive. Structurally, the more dry wall tape used, the stronger the repair.
Another kind of repair that can be done to repair large cracks and holes is to use a scrap piece of sim- ilar plastic and bond with structural adhesive. The reinforcement should cover the entire break and should have a generous amount of overlap on either side of the cracked or broken area.
When repairing plastic, the damaged area is first “V’d” out, or beveled. Large bonding areas are desir- able when repairing plastic because small repairs are less likely to hold permanently. Beveling the area around a crack at a 20 degree angle will increase the bonding surface for a repair (Fig. 4). It is recom- mended that sharp edges be avoided because the joint may show through after the panel is refinished.
Fig.1PANELSECTIONING
1 - EXISTING PANEL 2 - NEW PANEL 3 - PANEL ADHESIVE 4 - BONDING STRIP
When bonding plastic panels, Follow repair mate- rial manufacturers recommendations. Be sure that enough adhesive has been applied to allow squeeze out and to fill the full bond line. Once the pieces have been brought together, do not move them until the adhesive is cured. The assembly can be held together with clamps, rivets, etc. A faster cure can be obtained by heating with a heat lamp or heat gun. After the parts have been bonded and have had time
DR BODY (Continued)
BODY
23 - 7
ment can cause stress in the repair areas and can result in future failure.
Fig.2SOFTENEDEDGES
1 - SOFTENED EDGES 2 - PANEL ADHESIVE 3 - BONDING STRIP
Fig.3PANELREINFORCEMENT
1 - PANEL ADHESIVE 2 - REINFORCEMENT
Fig.5FIBERGLASSTAPE
VISUAL INSPECTION
Composite materials can mask the severity of an accident. Adhesive bond lines, interior structure of the doors, and steel structures need to be inspected carefully to get a true damage assessment. Close inspection may require partial removal of interior trim or inner panels.
Identify the type of repair: Puncture or Crack - Damage that has penetrated completely through the panel. Damage is confined to one general area; a panel section is not required. However, a backer panel, open fiberglass tape, or matted material must be bonded from behind (Fig. 7) (Fig. 6).
Fig.4BEVELINGANGLE-20DEGREE
† Panel repair for both flexible and rigid panels are basically the same. The primary difference between flexible panel repair and rigid panel repair is in the adhesive materials used (Fig. 5). † The technician should first decide what needs to be done when working on any type of body panel. One should determine if it is possible to return the damage part to its original strength and appearance without exceeding the value of the replacement part. † When plastic repairs are required, it is recom- mended that the part be left on the vehicle when every possible. That will save time, and the panel will remain stationary during the repair. Misalign-
Fig.6DAMAGECOMPONENT
1 - PUNCTURE
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the panel to achieve a successful repair. All spider web cracks leading away from a damaged area must be stopped or removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the crack farthest away from the damage. If spider web cracks can not be stopped, the panel would require replacement. The surfaces around the damaged area
BODY
23 - 8
BODY (Continued)should be stripped of paint and freed from wax and oil. Scuff surfaces around repair area with 360 grit wet/dry sandpaper, or equivalent, to assure adhesion of repair materials.
PATCHING PANELS
An panel that has extensive puncture type damage can be repaired by cutting out the damaged material (Fig. 7). Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is dam- aged. The piece cut out can be used as a template to shape the new patch. It is not necessary to have access to the back of the panel to install a patch. Bevel edges of cutout at 20 degrees to expose a larger bonding area on the outer side. This will allow for an increased reinforcement areas.
Fig.7DAMAGEDPANELCUTOUTANDPATCH
1 - CUTOUT 2 - DAMAGED BODY PANEL 3 - 4 MM (0.160 IN.) HOLES 4 - PATCH CUT TO SIZE
PANEL PATCH FABRICATIONS
A patch can be fabricated from any rigid fiberglass panel that has comparable contour with the repair area. Lift gates and fenders can be used to supply patch material. If existing material is not available or compatible, a patch can be constructed with adhe- sive and reinforcement mesh (dry wall tape). Perform the following operation if required:
(1) Cover waxed paper or plastic with adhesive backed nylon mesh (dry wall tape) larger than the patch required (Fig. 8).
(2) Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area.
(3) Apply a liberal coat of adhesive over the rein- forcement mesh (Fig. 8). If necessary apply a second or third coat of adhesive and mesh after firs coat has cured. The thickness of the patch should be the same as the repair area.
DR
(4) After patch has cured, peel waxed paper or
plastic from the back of the patch.
(5) If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh for added strength.
Fig.8FABRICATEDPANEL
1 - STRUCTURAL ADHESIVE 2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE 3 - WIDTH OF V-GROOVE 4 - WAXED PAPER
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the size
and shape of the cutout hole in the panel.
(2) Trim 3 mm (0.125 in.) from edges of pattern so
patch will have a gap between connecting surfaces.
(3) Using the pattern as a guide, cut the patch to
size.
(4) Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to sustain the patch in the cutout.
(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in
from edge of cutout hole (Fig. 7).
(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around cutout.
(7) Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center of one side.
(8) Scuff the backside of the body panel around the
cutout hole with a scuff pad or sandpaper.
(9) Mix enough adhesive to cover one side of all
(10) Apply adhesive to cover one side of all support
support squares.
squares.
(11) Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive sandwiched between the panel and squares (Fig. 9).
(12) Position patch in cutout against
support squares and adjust patch until the gap is equal along all sides (Fig. 10).
DR BODY (Continued)
BODY
23 - 9
Fig.9SECURESUPPORTSQUARESTOBODY
PANEL
1 - SUPPORT SQUARES 2 - SCREWS 3 - DAMAGED BODY PANEL
Fig.10POSITIONPATCHINCUTOUTANDALIGN 1 - CUTOUT 2 - SUPPORT SQUARES
(13) Drill 3 mm (0.125 in.) holes in the support
squares through the pre-drilled holes in the patch.
(14) Apply a coat of adhesive to the exposed ends
of the support squares (Fig. 11).
(15) Install screws to hold the patch to support squares (Fig. 12). Tighten screws until patch surface is flush with panel surface.
(16) Allow adhesive to cure, and remove all screws. (17) Using a 125 mm (5 in.) 24 grit disc grinder, grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the patch (Fig. 13). With compressed air, blow dust from around patch.(18) Apply adhesive backed nylon mesh (dry wall
tape) over gaps around patch (Fig. 14).
(19) Mix enough adhesive to cover the entire patch
area.
(20) Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce fin- ish grinding. Use two to three layers of mesh and adhesive to create a stronger repair (Fig. 15).
Fig.11APPLYADHESIVETOSUPPORTSQUARES 1 - APPLICATOR 2 - SUPPORT SQUARES 3 - ADHESIVE
BODY
23 - 10
BODY (Continued)DR
Fig.12INSTALLSCREWS
Fig.14COVERGAPSWITHMESH
1 - PATCH 2 - GAP
1 - GROUND DOWN AREA 2 - PATCH 3 - MESH
Fig.13GRINDSURFACE
Fig.15COVERMESHWITHADHESIVE
1 - PATCH 2 - GAP 3 - DISC GRINDER
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can be finished using the same methods as finishing other types of body panels. If mesh material is exposed in the patched area, grind surface down, and apply a coat of high quality rigid plastic body filler. Prime, block sand, and paint as required.
1 - ADHESIVE 2 - MESH 3 - PATCH 4 - SPREADER
DR BODY (Continued) STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE
Buzz, Squeak & Rattles (BSR) may be caused by any one or more of the following and may be cor- rected as indicated: † Loose fasteners should be tightened to specifica- tions.† Damaged or missing clips should be replaced. † Damaged trim panels should be replaced.
BODY
23 - 11
† Incorrectly installed trim panels should be rein-
stalled properly.
Many BSR complaints such as loose trim, can be serviced using the Mopart Parts BSR Noise Reduc- tion Kit. This kit contains various tapes including foam, flock and anti-squeak used to eliminate noises caused by metal, plastic and vinyl components. Long life lubricants and greases can also be used on a vari- ety of components. Refer to the Buzz, Squeak & Rat- tle Kit table for material contents and usage.
BUZZ, SQUEAK & RATTLE KIT
FEATURES
APPLICATIONS
SERVICE TEMP
ITEM
Itch And Squeak Tape
Black Nylon Flock
An abrasion resistant material thin enough to conform to most irregular surfaces. Stops most itches and squeaks.
Nylon Flock with an aggressive acrylic adhesive. Provides for cushioning and compression fit, also isolates components. Water-resistant.
High Density Urethane Foam
Tear resistant, highly resilient and durable.
Open Cell Foam Tape
Soft foam conforms to irregular surfaces.
Closed Cell Low Density Foam Tape
Soft, conformable. Water- resistant.
NYET Grease 880
Long life.
KrytoxT Oil
Long life. Will not dry out or harm plastics or rubber.
KrytoxT Grease
Long life. Will not dry out or harm plastics or rubber.
Between metal and metal, metal and plastic, metal and vinyl, vinyl and plastic. Interior. Examples: Trim panels and bezels. Between metal and metal, metal and plastic, vinyl and plastic. Examples: Pull cups, bezels, clips, ducts, top cover to glass, cowl panel. Between metal and metal, metal and plastic. Water- resistant. Examples: I/P, heavy metal rattles, isolating brackets. Wire harness and connector wrap. Examples: Seals, gasket, wiring, heat ducts. Wherever bulk is needed. Prevents closing flutters and rattles when applied to door watershield. Examples: Door, I/P. Suspensions. Examples: Strut busings, sway bars.
When access is not possible, oil will migrate to condition. Vinyl, rubber, plastic, metal. Examples: Convertible top bushings, pull cups trim panel inserts. Vinyl, rubber, plastic, metal, glass. Examples: Weather-strips, backlite and windshield moldings.
-40° to 225° Fahrenheit (-40° to 107° Celsius)
-40° to 180° Fahrenheit (-40° to 82° Celsius)
-40° to 180° Fahrenheit (-40° to 82° Celsius)
-40° to 180° Fahrenheit (-40° to 82° Celsius)
-40° to 180° Fahrenheit (-40° to 82° Celsius)
-40° to 390° Fahrenheit (-40° to 200° Celsius) -30° to 400° Fahrenheit (-34° to 205° Celsius)
-30° to 400° Fahrenheit (-34° to 205° Celsius)
BODY
23 - 12
BODY (Continued) SPECIFICATIONS - TORQUETORQUE SPECIFICATIONS
DR
Description
A-pillar trim/grab handle bolts
Body Isolator/cab bolts
Cargo box bolts
Cargo box tie down/cleat bolts
Center seat assembly nuts*
Center seat cushion/hinge bolts*
Center seat back hinge to storage bin bolts*
Center seat back free pivot hinge bolt* Center seat back inertia hinge pivot bolt*
Center seat inertia hinge to seat back bolts*
Fender bolts - front lower Fender bolts - lower inside
Fender to hinge support bolts
Fender to upper fender rail bolts
Footmans loop bolts Front center seat nuts*
Front door glass lift plate nuts Front door hinge to a-pillar nuts
Front door hinge to door nuts/bolts
Front door inside handle bolt
Front door latch adjustment screw
Front door latch assembly bolts
Front door latch striker bolts Front door latch striker bolts
Front door regulator bolts
Front door regulator stabilizer nuts
Front door remote handle actuator nuts
Front door run channel screws Front seat assembly front bolts* Front seat assembly rear bolts*
Front seat track nuts*
Fuel fill door bolts
Hood hinge to fender rail bolts
Hood latch bolts
Hood latch striker/safety catch bolts
Hood hinge to hood nuts
Instrument panel center bracket bolts Instrument panel column support bolts Instrument panel side mounting bolts
N·m
Ft. Lbs.
In. Lbs.
81
108
34
25
20
25
25
10
25
17
11
12
25
10
28
28
10
28
28
10
10
10
10
28
40
25
20
11
11
23
12
14
12— 60
80
25
18
15
18
18
— 18
— 13
— 18
— 21
21
— — — 21
21
— — — — 30
30
18
— 15
17
1055
— — — — — — — 89
— 80
— — 80
— — 89
— — 80
30
89
— — 89
89
89
89
— — — 80
— — — — — — —DR BODY (Continued)
Description
Instrument panel top bolts
Load floor nuts
Load floor/rear seat bolts
Overhead/b-pillar grab handle bolts
Radiator and condenser to radiator crossmember bolts
Radiator upper crossmember bolts
Rear door glass lift plate nuts Rear door glass run channels Rear door hinge to b-pillar bolts
Rear door hinge to door bolts/nuts
Rear door inside handle bolt
Rear door latch adjustment screw
Rear door latch bolts
Rear door latch striker bolts
Rear door regulator bolts
Rear door regulator stabilizer nuts
Rear door remote handle actuator nuts
Rear fender bottom screws
Rear fender nuts
Rear fender support bracket bolts
Rear seat assembly bolts* Rear seat back hinge bolts*
Rear seat cushion hinge bolts* Rear shoulder belt anchor bolts
Rear view mirror set screw
Shifter knob nut
Side view mirror nuts
Tailgate check cable bolt Tailgate hinge/pivot screws
Tailgate latch bolts Tailgate latch striker
Tailgate release handle nuts
NOTE: *Seat replaced with new fasteners during assembly.
fasteners should be discarded and
BODY
23 - 13
Ft. Lbs.
In. Lbs.
18
30
— — 21
— — 21
21
— — — 21
— — — — — 30
18
24
30
— 20
— 17
25
17
25
—— — — 55
75
— 89
89
— — 80
30
89
— 89
89
89
60
60
— — — — — 15
— 60
— — — — 60N·m 12
25
40
28
10
10
28
28
10
28
10
10
10
11
40
25
32
40
27
23
34
23
34BODY
23 - 14
BODY (Continued) SPECIAL TOOLSBODY
DR
TrimStickC-4755
TorxBitSetC-4794-B
MoldingRemoverC-4829
DR
TAILGATE
23 - 15
TAILGATE
TABLE OF CONTENTS
page
page
CHECK CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17RELEASE HANDLE/LATCH REMOTE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17TAILGATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17CHECK CABLE REMOVAL
(1) Open tailgate. (2) Pry lock tab outward to clear stud head on
cargo box (Fig. 1).
(3) Push cable end forward until stud head is in
clearance hole portion of cable end. (4) Separate cable end from stud. (5) Remove screw attaching cable to tailgate. (Fig.
2)
(6) Separate check cable from tailgate.
Fig.2LATCHHANDLE-LATCH
1 - EXTERIOR HANDLE 2 - CONTROL ASSEMBLY 3 - NUTS (2) 4 - TAILGATE 5 - LATCH 6 - CHECK CABLE 7 - CHECK/LATCH BOLT 8 - LATCH BOLT
INSTALLATION
Fig.1TailgateCheck
1 - TAILGATE STRIKER 2 - SCREW DRIVER 3 - TAILGATE CHECK CABLE 4 - LOCK TAB
(1) Position check cable on tailgate. (2) Install bolt attaching small end of cable to tail-
(3) Tighten tailgate check cable bolt to 23 N·m (17
gate.
ft. lbs.).
(4) Position large end of cable onto stud head and
slide downward to secure lock tab.
23 - 16
TAILGATE
COVER REMOVAL
DR
(1) Open the tailgate. (2) Remove the eight screws and remove tailgate
liner, if equipped.
(3) Remove the bolts and remove the cover. (Fig. 3)
Fig.4TAILGATEHINGE
1 - HINGE/PIVOT 2 - TAILGATE PILLAR 3 - CLIP/BUSHING 4 - BOLTS (2)
LATCH REMOVAL
(1) Remove the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
actuator rod for installation.
(3) Disconnect assembly. (Fig. 3)
the actuator rod at
the control
(4) Remove the latch bolt and the check cable bolt.
(5) Remove the latch and actuator rod assembly.
INSTALLATION
(1) Install the latch and actuator rod assembly. (2) Install the latch and the check cable bolts and
tighten to 23 N·m (17 ft. lbs.).
(3) Connect the actuator rod to the control assem-
bly line up the marks made during removal.
(4) Install the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - INSTALLATION)
Fig.3TAILGATEASSEMBLY
1 - LATCH ASSEMBLY 2 - CONTROL ASSEMBLY 3 - ACTUATOR ROD (2) 4 - COVER 5 - BOLTS (10)
INSTALLATION
(1) Install the cover and install the bolts and
(Fig. 5)
tighten by hand.
(2) Install
the liner and install
the screws,
if
equipped.
HINGE REMOVAL
(1) Remove the tailgate.
(Refer to 23 - BODY/
TAILGATE/TAILGATE - REMOVAL)
(2) Remove the two screws and remove the hinge/
pivot. (Fig. 4)
INSTALLATION
(1) Install the hinge/pivot and install the screws. (2) Tighten the screws to 34 N·m (25 ft. lbs.). (3) Install the tailgate. (Refer to 23 - BODY/TAIL-
GATE/TAILGATE - INSTALLATION)
DR
TAILGATE
23 - 17
LATCH STRIKER REMOVAL
(1) Open tailgate. (2) Using a grease pencil or equivalent, mark out- line of striker on cargo box jamb to aid installation. (3) Using a Torx drive wrench, remove striker and
washer from cargo box.
INSTALLATION
(1) Position striker and washer on jamb using alignment outline as reference and install with Torx drive wrench.
(2) Tighten the striker to 34 N·m (25 ft. lbs.).
RELEASE HANDLE/LATCH REMOTE REMOVAL
(1) Remove the tailgate cover. (Refer to 23 - BODY/
TAILGATE/COVER - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
latch actuator rods for ease of installation.
(3) Disconnect the latch actuator rods. (Fig. 3) (4) Remove the control assembly nuts and remove the control assembly and the exterior handle. (Fig. 5)
Fig.5LATCHHANDLE-LATCH
1 - EXTERIOR HANDLE 2 - CONTROL ASSEMBLY 3 - NUTS (2) 4 - TAILGATE 5 - LATCH 6 - CHECK CABLE 7 - CHECK/LATCH BOLT 8 - LATCH BOLT
INSTALLATION
lbs.).
(1) Install the handle and the control assembly. (2) Install the nuts and tighten to 7 N·m (60 in.
(3) Connect the actuator rods using the marks
made during removal.
(4) Install the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - INSTALLATION)
TAILGATE REMOVAL
(1) Open the tailgate. (2) Disconnect the tailgate check cables (Fig. 6). (Refer to 23 - BODY/TAILGATE/CHECK CABLE - REMOVAL)
(3) Close tailgate until the notch in the right hand
collar aligns with the pivot pin.
(4) Slip tailgate hinge collar from pivot pins. (5) Slide tailgate to the right and separate left
hand collar from the pivot pin.
(6) Separate tailgate from vehicle.
Fig.6TAILGATEASSEMBLY
1 - LATCH STRIKER 2 - CHECK CABLE BOLT 3 - CHECK CABLE 4 - TAILGATE 5 - HINGE BUSHING
INSTALLATION
(1) Position tailgate collar on left hand pivot pin
and slide tailgate to the left.
(2) Raise tailgate until the notch in the right hand
collar aligns with the pivot pin.
(3) Connect the tailgate check cables. (Refer to 23 - INSTALLA-
BODY/TAILGATE/CHECK CABLE - TION)
23 - 18
DOOR - FRONT
DOOR - FRONT
TABLE OF CONTENTS
page
DR
page
DOOR
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 24
DOOR GLASS
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24EXTERIOR HANDLE
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24GLASS RUN CHANNEL
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25HINGE
WINDOW REGULATOR - POWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25INSIDE HANDLE ACTUATOR
WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 23
SIDE VIEW MIRROR FLAG
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27INSTALLATION
(1) Support the door with a suitable lifting device
and install the door onto the hinges.
(2) Install the washers, if there were removed pre-
viously, nuts and tighten to 28 N·m (21 ft. lbs.).
(3) Connect the electrical connectors. (4) Adjust the door as necessary. (Refer to 23 -
BODY/DOOR - FRONT/DOOR - ADJUSTMENTS)
DOOR REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the A-pillar. (Fig. 1)
(2) Using a grease pencil or equivalent, mark the outline of the door hinges on the door to aid in instal- lation.
(3) Support the door with a suitable lifting device.
NOTE: The epoxy bonded washers should not be seperated from the hinge. the washers are removed the door may have to be re-adjusted.
If
(4) Remove the nuts and bolts attaching the door
hinges to the door.
DR DOOR (Continued)
DOOR - FRONT
23 - 19
(3) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(4) Tighten the hinge pillar fasteners to 28 N·m
(21 ft. lbs.).
UP/DOWN
NOTE: Up/down door adjustment is done by loosen- ing either the hinge to the hinge pillar fasteners or the hinge to door fasteners and moving the door to the correct position.
NOTE: When adjustment of the door requires the loosening of the door to hinge fasteners, it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool.
NOTE: When the up/down adjustments are done correctly, the top of the door is positioned over flush to the roof. (Refer to 23 - BODY/BODY STRUC- TURE/GAP AND FLUSH - SPECIFICATIONS)
(1) Support the door with a suitable lifting device. (2) Loosen the latch striker bolts. (Refer to 23 -
FRONT/LATCH STRIKER
BODY/DOOR REMOVAL)
(3) Loosen the hinge to door fasteners (Refer to 23
- BODY/DOOR - FRONT/DOOR - REMOVAL) or loosen the hinge to hinge pillar fasteners (Refer to 23
- BODY/DOOR - FRONT/HINGE - REMOVAL).(4) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(5) Tighten the hinge pillar fasteners or the door
to hinges fasteners to 28 N·m (21 ft. lbs.).
(6) Tighten the latch striker bolts. (Refer to 23 - BODY/DOOR - FRONT/LATCH STRIKER - INSTAL- LATION)
IN/OUT
NOTE: In/out door adjustment is done by loosening the hinge to door fasteners one hinge at a time and moving the door to the correct position.
NOTE: When adjustment of the door requires the loosening of the door to hinge fasteners, it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool.
(1) Support the door with a suitable lifting device. (2) Loosen the latch striker bolts. (Refer to 23 -
FRONT/LATCH STRIKER
BODY/DOOR REMOVAL)
Fig.1FRONTDOOR
1 - NUTS (2) 2 - UPPER HINGE 3 - STUDS 4 - FRONT DOOR 5 - WIRE HARNESS 6 - LOWER HINGE 7 - ELECTRICAL CONNECTORS (2) 8 - BOLTS (2)
ADJUSTMENTS
ADJUSTMENT
NOTE: For vehicles with four doors, it is recom- mended that you adjust the rear door before adjust- ing the front door. (Refer to 23 - BODY/DOORS - REAR/DOOR - ADJUSTMENTS) † Door adjustment measurements should be taken from stationary or welded body panels like the roof, rocker or quarter panels. † During adjustment procedures, is recom- mended that all the hinge fasteners be loosened except for the upper most fasteners. Adjustments can be made using the upper bolts to hold the door with final torque of the fasteners occurring after correct door positioning is achieved. † A suitable body sealant should be used when removing or moving the hinges.
it
FORE/AFT
NOTE: Fore/aft (lateral) door adjustment is done by loosening the hinge to the hinge pillar fasteners one hinge at a time and moving the door to the cor- rect position.
(1) Support the door with a suitable lifting device. (2) Loosen the hinge to hinge pillar fasteners. (Refer to 23 - BODY/DOOR - FRONT/HINGE - REMOVAL)
DR
INSTALLATION
(1) Position the glass into the window opening. (2) Engage the glass into the glass run weather-
strip.
lbs.).
(3) Raise the glass within the door opening and
connect the window regulator to the lift plate.
(4) Install the nuts and tighten to 10 N·m (89 in.
(5) Install the inner belt molding. (Refer to 23 - BODY/WEATHERSTRIP/SEALS/FRONT DOOR INNER BELT WEATHERSTRIP - INSTALLATION) (6) Position the front run channel and install the screws. (Refer to 23 - BODY/DOOR - FRONT/GLASS RUN CHANNEL - INSTALLATION)
(7) Remove the window switch from the wire har-
ness, if equipped.
(8) Remove the window handle, if equipped. (9) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
EXTERIOR HANDLE REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Disconnect the lock switch electrical connector,
if equipped. (Fig. 3)
(3) Disconnect the actuator rods at the handle. (4) Remove the nuts and remove the handle.
INSTALLATION
(1) Install the exterior handle and install the nuts. (2) Connect the actuator rods at the handle (3) Connect the lock switch electrical connector, if
equipped.
(4) Install the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - INSTALLATION)
DOOR - FRONT
23 - 20
DOOR (Continued)(3) Loosen the hinge to door fasteners. (Refer to 23
- BODY/DOOR - FRONT/DOOR - REMOVAL)
(4) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(5) Tighten the door to hinges fasteners to 28 N·m
(21 ft. lbs.).
(6) Tighten the latch striker bolts. (Refer to 23 - BODY/DOOR - FRONT/LATCH STRIKER - INSTAL- LATION)
DOOR GLASS REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Reinstall the window handle, if equipped. (3) Remove the window switch from the door trim panel and reconnect it to the door wire harness, if equipped.
(4) Raise the window to the position shown and remove the two nuts attaching the glass to the win- dow regulator. (Fig. 2)
(5) Remove the two front run channel screws. (Refer to 23 - BODY/DOOR - FRONT/GLASS RUN CHANNEL - REMOVAL)
(6) Remove the inner belt molding. (Refer to 23 - DOOR
BODY/WEATHERSTRIP/SEALS/FRONT INNER BELT WEATHERSTRIP - REMOVAL)
(7) Disengage the glass from the regulator and
lower into the door.
opening and remove.
(8) Twist the glass forward in the door window
Fig.2DOORGLASSPOSITIONING
1 - SIGHT WINDOW 2 - WIDOW REGULATOR 3 - SIGHT WINDOW 4 - REGULATOR STABILIZER
DR EXTERIOR HANDLE (Continued)
DOOR - FRONT
23 - 21
Fig.3EXTERIORHANDLE
Fig.4FRONTRUNCHANNEL
1 - FRONT GLASS RUN CHANNEL 2 - UPPER SCREW 3 - LOWER SCREW 4 - DOOR PANEL OPENING 5 - RUN CHANNEL MOUNTING SLOTS (2)
1 - EXTERIOR HANDLE 2 - NUTS (2) 3 - ELECTRICAL CONNECTOR 4 - FRONT DOOR 5 - DOOR LATCH ASSEMBLY 6 - LATCH ACTUATOR ROD 7 - LOCK SWITCH WIRE HARNESS 8 - KEY CYLINDER ACTUATOR ROD
GLASS RUN CHANNEL REMOVAL
(1) Raise glass into the full up position. (2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
FRONT RUN CHANNEL
(1) Remove the window regulator. (Refer to 23 - BODY/DOOR - FRONT/WINDOW REGULATOR - REMOVAL)
(2) Loosen the front run channel screws, slide up
and disengage from the door. (Fig. 4)
(3) Separate the glass run weatherstrip from the
channel and remove the front channel.
REAR RUN CHANNEL
(1) On standard cab models, remove the screws
from the side of the door. (Fig. 5)
(2) On quad cab models, remove the lower screw from the side of the door, loosen the upper screw and disengage from the door. (Fig. 6)
(3) Separate the glass run weatherstrip from the
rear channel and remove the channel.
Fig.5REARRUNCHANNEL-QUADCAB
1 - SCREWS 2 - REAR GLASS RUN CHANNEL 3 - DOOR PANEL OPENING
INSTALLATION
FRONT RUN CHANNEL
(1) Install the channel, position the screws in the
door panel slots and slide into place.
(2) Tighten the screws to 10 N·m (89 in. lbs.).
DOOR - FRONT
23 - 22
GLASS RUN CHANNEL (Continued)DR
INSTALLATION
(1) Install the hinges and bolts. (2) Tighten bolts to 28 N·m (21 ft. lbs.). (3) Install the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - INSTALLATION)
INSIDE HANDLE ACTUATOR REMOVAL
(1) Remove the screw and remove the inside han-
dle. (Fig. 7)
(2) Remove the door trim panel. (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Disconnect the latch actuator rod. (Fig. 8) (4) Remove the nuts and remove the remote han-
dle actuator.
Fig.6REARRUNCHANNEL-STANDARDCAB
1 - LOWER SCREW 2 - DOOR PANEL OPENING 3 - REAR GLASS RUN CHANNEL 4 - UPPER SCREW
(3) Install the window regulator. (Refer to 23 - BODY/DOOR - FRONT/WINDOW REGULATOR - INSTALLATION)
REAR RUN CHANNEL
(1) On quad cab models, install the channel and
slide the upper screw into the slot.
(2) Install the lower screw and tighten both upper
and lower screws to 10 N·m (89 in. lbs.).
(3) On standard cab models, install the channel
and install the screws.
(4) Tighten the screws to 10 N·m (89 in. lbs.).
BOTH CHANNELS
(1) Stuff the glass run weatherstrip into the chan-
nels.
(2) Verify correct window operation. (3) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
the nuts.
HINGE REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
hinge location and remove the bolts.
Fig.7INSIDEHANDLEACTUATOR
1 - BOLT 2 - HANDLE 3 - TRIM PANEL OPENING
INSTALLATION
(1) Install the remote handle actuator and install
(2) Tighten the nuts to 10 N·m (89 in. lbs.). (3) Connect the latch actuator rod. (4) Install the door trim panel.
(Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - INSTALLA- TION)
(5) Install the inside handle and install the bolt. (6) Tighten the bolt to 9 N·m (80 in. lbs.).
DR INSIDE HANDLE ACTUATOR (Continued)
DOOR - FRONT
23 - 23
Fig.8REMOTEHANDLEACTUATOR
Fig.9LATCHASSEMBLY
1 - DOOR 2 - ELECTRICAL CONNECTOR 3 - LATCH ASSEMBLY 4 - BOLTS
(2) Insert a 5/32-inch hex-wrench through hole and
into adjustment screw. Loosen screw.
(3) Operate outside handle several times to release
any restriction because of mis-alignment.
(4) Tighten adjustment screw to 3 N·m (30 in.
(5) Test handle for proper operation.
1 - DOOR 2 - LATCH ASSEMBLY 3 - LATCH ACTUATOR ROD 4 - NUTS (2) 5 - HANDLE REMOTE
LATCH REMOVAL
(1) Raise the window to the full up position. (2) Remove the waterdam. (Refer to 23 - BODY/
lbs.).
DOOR - FRONT/WATERDAM - REMOVAL)
(3) Disconnect the actuator rods. (4) Remove the bolts. (Fig. 9) (5) Disconnect the electrical connector and remove
the latch.
INSTALLATION
latch assembly.
lbs.).
(1) Connect the electrical connector and install the
(2) Install the bolts and tighten to 10 N·m (89 in.
(3) Connect the actuator rods. (4) Adjust the latch as needed.
(Refer to 23 -
BODY/DOOR - FRONT/LATCH - ADJUSTMENTS)
(5) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/LATCH - INSTALLATION)
ADJUSTMENTS
ADJUSTMENT
(1) Locate access hole and remove the mylar tape
covering it. (Fig. 10)
Fig.10LATCHADJUSTMENTSCREW-TYPICAL 1 - DOOR LATCH 2 - MYLAR TAPE 3 - ADJUSTMENT SCREW
23 - 24
DOOR - FRONT
LATCH STRIKER REMOVAL
DR
(1) Using a grease pencil or equivalent, mark the
position of the striker.
(2) Remove the bolts and remove the striker.
INSTALLATION
(1) Install the striker and install the bolts. (2) Tighten the bolts to 28 N·m (21 ft. lbs.). (3) Adjust the striker if needed.
(Refer to 23 - BODY/DOOR - FRONT/LATCH STRIKER - ADJUST- MENTS)
ADJUSTMENTS
ADJUSTMENT
(1) Using a grease pencil or equivalent, mark the
position of the striker to aid in adjustment.
(2) Loosen the striker bolts. (3) Change the striker position to adjust the rear gap and flush measurement. (Refer to 23 - BODY/ BODY STRUCTURE/GAP AND FLUSH - SPECIFI- CATIONS)
(4) Tighten the bolts to 28 N·m (21 ft. lbs.).
LOCK CYLINDER REMOVAL
(1) Remove the exterior handle.
(Refer to 23 - BODY/DOOR - FRONT/EXTERIOR HANDLE - REMOVAL)
(2) Remove the clip and remove the lock cylinder
lever and switch, if equipped.
(3) Remove the screw and remove the lock cylin-
der. (Fig. 11)
INSTALLATION
(1) Install the lock cylinder and install the screw. (2) Install the lock cylinder switch, if equipped,
lever and retaining clip.
(3) Install
the exterior handle.
(Refer to 23 - BODY/DOOR - FRONT/EXTERIOR HANDLE - INSTALLATION)
Fig.11LOCKCYLINDER
1 - LOCK CYLINDER 2 - EXTERIOR HANDLE 3 - SCREW 4 - LOCK SWITCH WIRE HARNESS
TRIM PANEL REMOVAL
(1) Remove the window crank, if equipped. (Fig.
13)
(2) Remove the interior handle.
(Refer to 23 - BODY/DOOR - FRONT/INSIDE HANDLE ACTUA- TOR - REMOVAL)
(3) Remove the screws at the mirror flag and near
the inside handle. (Fig. 12)
CAUTION: Trim panel is attached to the door using hooks molded into the panel. Do not pull the trim panel straight off or damage to the panel and/or power switch assembly may occur.
(4) Lift the trim panel up off the belt seal and attachment hooks and separate the panel from the door slightly.
(5) Disconnect the power window switch electrical
connector, if equipped, and remove the trim panel.
INSTALLATION
(1) Install the window switch into the trim panel,
if equipped.
(2) Position the trim panel onto the lower hooks and connect the power window switch electrical con- nector, if equipped.
(3) Position the remaining trim panel attachment hooks into the door panel and seat the trim panel into the belt seal fully.
DR TRIM PANEL (Continued)
DOOR - FRONT
23 - 25
the waterdam becomes contaminated or dam-
If aged, replace the waterdam.
(1) Remove the inside handle actuator. (Refer to 23
- BODY/DOOR - FRONT/INSIDE HANDLE ACTUA- TOR - REMOVAL)(2) Remove the speaker. (Refer to 8 - ELECTRI-
CAL/AUDIO/SPEAKER - REMOVAL)
(3) Separate the waterdam from the inner door
panel and off of the latch linkages.
INSTALLATION
CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. Do not damage the waterdam during removal and installation. If aged, replace the waterdam.
the waterdam becomes contaminated or dam-
(1) Position the wire harness and actuator rods
through the holes in the waterdam.
(2) Secure the waterdam to the inner door panel. (3) Install the speaker. (Refer to 8 - ELECTRICAL/
AUDIO/SPEAKER - INSTALLATION)
(4) Install the inside handle actuator. (Refer to 23 - BODY/DOOR - FRONT/INSIDE HANDLE ACTUA- TOR - INSTALLATION)
WINDOW REGULATOR - POWER REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Remove the window switch from the door trim
panel and reconnect it to the door harness.
(3) Raise the window to the position shown and
remove the nuts. (Fig. 14)
(4) Disengage the door glass from the regulator lift
plate and position into the full up position.
(5) Secure the glass in the up position using a
wood wedge or equivalent. (6) Lower the regulator. (7) Remove the stabilizer nuts. (8) Remove the forward regulator bolt and loosen
(9) Slide the regulator up and out of the keyhole
the other two. (Fig. 15)
slots in the door panel. the
(10) Disconnect
remove the regulator.
electrical
connector
and
INSTALLATION
(1) Install the regulator through the door panel
opening and connect the electrical connector.
Fig.12TRIMPANELASSEMBLY
1 - SCREW INSERT (2) 2 - SCREWS (2) 3 - DOOR TRIM PANEL 4 - LOWER SCREWS (3) 5 - ATTACHMENT HOOKS
Fig.13WINDOWCRANKREMOVALTOOL
1 - WINDOW CRANK REMOVAL TOOL 2 - WINDOW CRANK
(4) Install the screws near the inside handle and
at the mirror flag.
(5) Install
the interior handle.
(Refer to 23 - BODY/DOOR - FRONT/INSIDE HANDLE ACTUA- TOR - INSTALLATION)
(6) Install the window crank, if equipped.
WATERDAM REMOVAL
CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. Do not damage the waterdam during removal and installation.
DOOR - FRONT
23 - 26
WINDOW REGULATOR - POWER (Continued)Fig.14DOORGLASSPOSITIONING
1 - SIGHT WINDOW 2 - WIDOW REGULATOR 3 - SIGHT WINDOW 4 - REGULATOR STABILIZER
Fig.15WINDOWREGULATOR-POWER
1 - REGULATOR STABILIZER 2 - INNER DOOR PANEL 3 - STABILIZER NUTS (2) 4 - REGULATOR 5 - FORWARD BOLT 6 - WIRE HARNESS 7 - BOLTS (2)
(2) Position the regulator bolts into the keyhole
slots and slide into place.
(3) Install the forward bolt and tighten all three to
10 N·m (89 in. lbs.).
DR
install the nuts and
(4) Position the stabilizer,
tighten to 10 N·m (89 in. lbs.).
(5) Raise the regulator to the position shown in
(Fig. 14).
regulator lift plate.
(89 in. lbs.).
the door trim panel.
(6) Remove the glass support and connect to the
(7) Install the glass nuts and tighten to 10 N·m
(8) Disconnect the window switch and install into
(9) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
WINDOW REGULATOR - MANUAL REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Reinstall the window handle and raise the win- dow to the position shown and remove the nuts. (Fig. 14)
(3) Disengage the door glass from the regulator lift
plate and position into the full up position.
(4) Secure the glass in the up position using a
wood wedge or equivalent. (5) Lower the regulator. (6) Remove the stabilizer nuts. (7) Remove the two lower and loosen the two
upper bolts. (Fig. 16)
(8) Slide the regulator up and out of the keyhole
(9) Remove the regulator from the door panel
slot.
opening.
INSTALLATION
inner door panel.
(1) Install the regulator through the hole in the
(2) Position the regulator and slide the upper bolts
