JK Top Water Leak Part #1
Contents
1. STEP 2 A Pillar Foam e NOTE This issue repair applies to both hard and soft top vehicles e Inspect the freedom panel or side rail for damaged missing foam Figure 10 e If the foam is damaged or missing replace the foam using the foam kit 68026937AB Figure 11 3 nu STEP 2 Foam installation gt e Install the foam to the freedom panel as shown in Figure 12 e The foam installation is similar for the soft top rail RH Panel Shown Figure 12 Labor Op Code J B Pillar Mucket Foam Seal Repair AREA OF LEAK e This repair procedure is applicable when water is evident on the o Instrument panel Center or o Console Shifter STEP 1 Seal Removal e Removesealon Right panel STEP 2 Tape and Butyl Removal e Remove tape and butyl residue from panel e A rubber wheel bit can be used e Clean Seal Surface with 3M General Purpose Adhesive Cleaner or Kent Products Acrysol if available and allow to dry completely e Wipe seal surface with alcohol and allow to dry completely Labor Op Code Figure 15 B Pillar Mucket Foam Seal Repair STEP 3 Butyl Installation e Place right hand freedom panel upside down on a covered surface to prevent scratching e Apply 4mm diameter Butyl Pt 68027813AA to Rear Notch Figure 17 e Note Follow groove between panels and push butyl firmly in place e Apply 4 mm diameter Butyl Pt 68027813AA to Front Notch2. Figure 18 e Note Follow groove between panels and push butyl firmly in place Labor Op Code Figure 16 Figure 17 Figure 18 B Pillar Mucket Foam Seal Repair STEP 4 Seal Installation e Keep freedom panel upside down for the initial installation of the seal e Remove tape liner from seal NOTE Secure the end molds first then finish with the middle of the seal Rear Seal Mold e Align REAR edge of NEW seal Pt 55397095AG to Right Freedom Panel Notch e Compress butyl by installing seal in direction of arrows Figure 20 e Note No gap between installed seal and outer edge of freedom panels Figure 20 Front Seal Mold e Align FRONT edge of NEW seal Pt 55397095AG to Right Freedom Panel Notch e Compress butyl by installing seal in direction of arrows Figure 21 e Note No gap between installed seal and outer edge of freedom panels Figure 21 Labor Op Code Figure 20 Figure 21 Rear Mold Front Mold 8 B Pillar Mucket Foam Seal Repair STEP 5 Pressurize Seal e Flip panel back over to complete the seal installation e Locate seal cross car against the middle rib in the freedom panel and pressurize starting at the ends and working toward the center e A small roller or firm finger pressure should be used to insure the seal tape is adhered from front to rear THIS STEP IS CRITICAL This photo is for reference only Panel was cut to show
3. Jeep Wrangler R Diagnosis amp Repair Manual Water Leaks Jeep General Notes 1 This manual applies to all Jeep models 2 4 door amp Hard Soft Top 2 Before testing the vehicle perform a review of the top system Make sure all the latches are engaged none of the top seals are puckered or distorted the door seals are installed correctly the tops are not out of alignment etc 3 Each leak area can have multiple root causes as noted in the diagnosis tree It is important to water test each repair before starting the next 4 If a leak cannot be reproduced it is due to the period of time the vehicle is under wet conditions Some leaks may take hours before leaking 5 If aleak cannot be reproduced apply all the repairs to the applicable areas as noted in the diagnosis road map 6 When the door is open there is water run off from the roof that can soak the carpet Be sure to explain to the customer that this cannot be fixed This is an unfortunate condition with this type of vehicle similar to convertibles 7 It is important to understand where the leak ENDS up when diagnosing the vehicle Where the leak ends up does not always explain where the leak originates Refer to the diagnosis tree when determining which repairs to perform 8 This repair procedure does NOT cover every possible water leak on the Jeep Wrangler The issues identified in this document are the major leaks that show up in the
4. up here pe MA 25937 ae Le FC A y j 7 PK Critical area to pressurize Figure 5 2 Door Fit Repair Procedure AREA OF LEAK e This repair procedure is applicable when water is evident on the o Door trim panel or o Instrument panel a pillar STEP 1 Door Gap Checks e Measure door gaps e The specifications are as follows e The gap spec is 5 0 2 0 mm TK e The flush spec is 0 0 2 0 mm e Ifthe door fit is not to spec proceed to Step 2 STEP 2 Adjust Doors e Adjust the door gap and flushness as described in DealerConnect gt TechCONNECT under Service info gt 23 Body gt Body Structure gt Gap and Figure 6 Flush gt Specifications Service Manual STEP 3 Replace Door Primary Seal e Ifthe doors are adjusted the door seal must be replaced e Part 55395274 5AN Labor Op Code 230010 Figure 7 3 A Pillar Foam Mucket Repair Procedure AREA OF LEAK e This repair procedure is applicable when water is evident on the o Door Trim Panel STEP 1 Header Mucket e NOTE This issue repair applies to both hard and soft top vehicles e Inspect the header seal mucket for the seal rolled under the freedom panel or side rail Figure 8 e If the seal is folded under remove the freedom panel or side rail and re install making sure not to distort the mucket Figure 9 Labor Op Code Figure 8 amp Le Figure 9 A Pillar Foam Mucket Repair Procedure
5. 10 Note Old Butyl Removed from Right Freedom Panel Front amp Rear Notches 10 14 2008 11 Place Right Freedom Panel Upside down on a covered Work surface to prevent paint scratching Freedom Panel Notch Buty installation 10 14 2008 12 Page 15 Rear notch Page 14 Front notch 10 14 2008 13 Apply New 4 mm diameter Butyl Pt 68027813AA to Right Freedom Panel Front Notch Note Follow Groove between panels and Push Butyl firmly inlplace Butyl inside Grooves arr 15 mm 10 14 2008 14 Apply New 4 mm diameter Butyl Pt 4 68027813AA to Right Freedom Panel Rear Notch Note Follow Groove between panels and Push Butyl firmlylin place T X pn Pat Butyl inside Grooves 10 14 2008 15 Page 17 Rear Weather Strip Page 18 Front Weather Strip Freedom Panel Weather Strip installation 10 14 2008 16 Align Rear edge of NEW Weather Strip Pt 55397095AG to Right Freedom Panel Notch Note No gap between installed Weather Strip and outer edge of freedom panels Compress butyl by installing Weather Strip in direction of Arrows t A smooth out Buty after a W Strip installation n Tia ni a A il 10 14 2008 17 Align Front edge of NEW Weather Strip Pt 55397095AG to Right Freedom Panel Notch Note No gap between installed Weather Strip and outer edge of freedom panels tyl after installation Note Remove Release tape and Press Weather Strip Firm
6. field 9 Generally a car wash is the preferred method to diagnose a vehicle 10 If a hose is required place on the top of the vehicle facing forward making sure water is getting to all areas Do NOT directly spray in the area of question This can create a false leak that cannot be fixed 11 This manual is not intended to be a service manual The content identifies the major areas of water leaks the critical characteristics of each area and how to repair them READ FIRST READ FIRST Diagnosis Road Map Water is on center of Instrument Water is on door trim panel or Water at Rear Hard Top Panel Water is on front carpet Panel Shifter Instrument Panel at A pillar B pillar Repair Procedures Area of leaks 11 Table of Contents I Diagnosis Road Map Il General Notes ji lll Water leak on Door Trim or Instrument Panel a Repair procedure for Windshield Header Seal 1 2 b Repair procedure for Door Fits 3 c Repair procedure for A pillar mucket foam 4 5 IV Water leak on Instrument Panel Console Center a Repair procedure for Freedom Panel Seal 6 11 b Repair procedure for Freedom Panel latches 11 V Water leak at B pir a Repair procedure for Hard Top Seal 12 14 b Repair procedure for B pillar Mucket 15 16 VI Water leak on front carpet a Repair procedure for rear wheel flare hole 17 18 b Repair procedure for cowl side leaks 19 20 Vil Appendix a Foam Kit 21 b Replacem
7. rib STEP 6 Install foam at Front e Install GREY 30 X 75 mm Foam from kit 68026937AB along trim lines of flame tip Figure 24 e NOTE Make sure foam covers butyl completely Labor Op Code Locator rib in panel Figure 22 Figure 23 Front of panel Figure 24 B Pillar Mucket Foam Seal Repair STEP 7 Install foam at Rear e Install BLACK 30 X 75 mm Foam from kit 68026937AB along trim lines of flame tip Figure 25 e NOTE Make sure foam covers butyl completely LEFT HAND FREEDOM PANEL STEP 8 Install butyl at Rear e Place Left hand freedom panel upside down on a covered surface to prevent scratching e Add 4mm diameter butyl 68027813AA to rear inboard corner groove Figure 27 e Note Push butyl firmly into groove between panels until flush Labor Op Code Figure 25 Figure 26 bas a Figure 27 10 B Pillar Mucket Foam Seal Repair STEP 9 Install foam at Rear e Add 30 X 75 mm Black Foam from Kit 68026937AB to cover butyl Figure 28 e NOTE Make sure foam covers butyl completely STEP 10 Install front latches e NOTE This applies to both Right and Left panels e Ifthe vehicle MDH is prior to 12 07 07 replace the front latches with part number 68004562AB Figure 29 Figure 29 11 Labor Op Code B Pillar Mucket Foam Seal Repair AREA OF LEAK e This repair procedure is applicable when water is evident on the o B pill
8. ar roll bar o B pillar trim o Freedom panel screw holes NOTE Water that enters anywhere along the hard top seal can travel over to the B pillar and leak from the hard top STEP 1 Inspect Hard Top Seal e Inspect for any gaps between the seal and hard top Figure 30 31 Labor Op Code B Pillar Mucket Foam Seal Repair STEP 1 Inspect Hard Top Seal e Inspect underneath the seal for any cont skips with the tape butyl along the entire seal Figure 34 amp 35 e Inspect the end molds for poor installation Figure 32 By er ILA KI m A A BAD GAP Figure 32 7 HOI GOOD GAP TAPE SKIP Figure 35 Figure 33 Labor Op Code 13 B Pillar Mucket Foam Seal Repair STEP 2 Replace Hard Top Seal If there are multiple skips or the leak cannot be stopped replace seal Remove all tape butyl and clean with alcohol prior to installation A rubber wheel bit can be used to remove the tape Apply butyl Pre apply butyl 68027813AA on as shown hard top prior to installing the seal Figure 36 It is critical that then end molds are Figure 36 installed correctly and sufficient pressure is applied to wet out the butyl tape Figure 36 pa A L UNGOErTIUS Figure 37 Labor Op Code 14 B Pillar Mucket Foam Seal Repair AREA OF LEAK e This repair procedure is applicable when water is evident on the o B plr trim or seat NOTE This repair applies
9. ent part numbers 22 111 Windshield Header Seal Repair Procedure AREA OF LEAK e This repair procedure is applicable when water is evident on the o Door trim panel or o Instrument panel a pillar STEP 1 Remove Header Seal e Figure 1 STEP 2 Remove Clean Surface e Remove all butyl and tape residue e A rubber wheel bit can be used e Clean surface with 3M adhesive cleaner e Alcohol wipe entire surface and allow to dry Figure 2 Labor Op Code 235135 1 Windshield Header Seal Repair Procedure STEP 3 STEP 4 Install Butyl NOTE This operation is only applicable for vehicles built before 6 1 2008 Vehicles built after this date should already have sealer present in this area Install 4mm butyl 68027813AA as shown Figure 4 Make sure to fill in all holes wrinkles and step offs to allow for a smooth surface to bond the tape butyl from the new seal NOTE Excessive amount of butyl can cause transition voids leaks Make sure to smooth out butyl Install Seal Locate and install new seal Pt 55397454AE Remove release tape and pressurize seal firmly in contact with header sheet metal to smooth out adhesive tape and butyl starting at the ends and working toward the center A small roller or firm finger pressure should be used to insure the tape is adhered completely from side to side THIS STEP IS CRITICAL Labor Op Code 235135 Figure 3 Figure 4 Line seal
10. es built prior to 5 28 08 will require this repair e Inspect the body for missing or mis aligned tape over the hole as seen in Figure 43 Add Replace a tape patch over the hole Hole 2 NOTE Vehicles built prior to 5 01 09 will reguire this repair e Inspect the body for missing or mis aligned tape over the hole as seen in Figure 43 Add Replace a tape patch over the hole Labor Op Code Leak Path x Figure 42 Figure 43 Rear Wheel Flare Hole Repair Hole G NOTE Vehicles built prior to 7 22 08 will require this repair e Cut the BLACK 30 x 75 foam from the foam kit 68026937AB in half and apply over this hole Figure 45 Make sure the foam does not extend past the flare trim line appearance issue Re install flare Figure 45 Labor Op Code 18 Cowl Side Panel Repair AREA OF LEAK e This repair procedure is applicable when water is evident on the o Front floor wet carpet NOTE These leaks can be diagnosed by applying a hose in the cowl panel Figure 47 Labor Op Code 235001 Figure 46 penses nase in cowl area a Figure 47 Cowl Side Panel Repair Condition 1 Mastic patches Plugs i Repair 1 Replace patch plug Condition 2 Check strap bracket Repair 2 Remove bracket and apply a butyl to holes Condition 3 Seam sealer skips Repair 3 Apply clear sealer part 04467708 to skip Condition 4 Scuff
11. ly in contact with Freedom Panel Front AND Rear 10 14 2008 18 Note Both Ends of new W Strip Located and installed to Freedom Panel Centers own unattached LES 10 14 2008 19
12. ter that drips into the Vehicle when the door is open This is a normal condition 10 14 2008 4 Foam Kit Contents These parts with Light Blue shaded 6802693 AB boxes are Optional Replace as required 20 mm x 95 mm x 5 mm 30 mm x 95 mm x 3 mm thick 2 pieces thick 2 pieces 2 Pair 7 7mm OD x 71mm 2 pieces fesse 13mm OD x 8mm ID x 160mm 1 piece 30 mm x 75mm x 2 mm thick 1 piece Gray Foam 4 M d di A A A 6 30 mm x 75mm x 3 mm thick 3 pieces Black Foam 9 mm x 100 mm x 6 35 mm thick 2 pieces 10 14 2008 These 4 pieces of foam are required for the freedom panel repair Additional Hard Top Foam Locations Included in the foam kit Replace as required 7 4 10 14 2008 6 r Right Freedom Panel Weather Strip Removal amp Freedom panel Cleaning 10 14 2008 Remove Right Freedom Panel Center Seal 10 14 2008 8 Remove old Butyl 8 Tape from Right Freedom Panel gt Sa 10 14 2008 9 Note Old Butyl Removed from Right Freedom Panel Seal Surface White Strip ko I d 4 sii a 22 ma A f PA 7 al N a A t sd millid DI ha A Pa e Clean Seal Surface with 3M General Purpose Adhesive Cleaner or Kent Products Acrysol if available and allow to dry completely Rough up Seal Surface with Medium Scotch Bright pad Wipe Seal Surface with Alcohol and allow to dry completely 10 14 2008
13. to 4 door hard top or soft top models STEP 1 Inspect mucket detail Inspect the mucket for a rolled under condition Figure 38 Inspect the mucket for a missing drain hole STEP 2 Replace the mucket detail If either of these conditions exist replace the mucket detail Fi 38 Part 55395708 9AE D Reinstall the panel or side rail making sure not to distort the mucket Figure 39 Labor Op Code 15 B Pillar Mucket Foam Seal Repair STEP 3 Inspect Freedom Panel for damaged or missing foam e If the foam is damaged or missing replace the foam using the foam kit 68026937AB RH Panel Shown STEP 4 Add additional foam to freedom panel Add a piece of foam to the freedom panel as shown in Figure 41 This foam can be created by cutting the 30 x 75mm GREY foam in half from the foam kit 68026937AB Figure 41 NOTE This foam is in addition to the foam that is already on the panel a ALLER om Li a Mama EM ul A CE a LN IA bi ml KA t Figure 41 Labor Op Code 16 Rear Wheel Flare Hole Repair AREA OF LEAK e This repair procedure is applicable when water is evident on the o Front floor wet carpet o Under seat NOTE This leak can be diagnosed by applying a hose to the upper rear flare and inspecting for water traveling along the floor to the front STEP 1 Remove Rear Flare STEP 2 Replace install Patch Hole NOTE Vehicl
14. trim foam damaged missing Repair 4 Replace trim clips Condition 5 Antenna grommet not seated Repair 5 Re install grommet Figure 48 Labor Op Code 235001 20 Appendix Foam Kit 68026937AB CHRYSLER sh 2137 AG LEET A B Pillar Foam 30 mm x 75mm BLACK Foam 30 mm x 75mm GREY Foam Used on Pages 5 16 Used on Pages 10 11 Used on Pages 9 16 Labor Op Code 21 Appendix Labor Op Code Jeep Wrangler Replacement Parts List KN Part Name Page S 68027813AA Butyl 27 104 04467708 Clear Sealer 120 68026937AB Foam Kit 5 9 11 16 55397454AE Windshield Header Seal 2 55395274 5AN Front Door Primary Seal 3 B Pillar Mucket 15 55397095AG Freedom Panel Seal 8 _55397046AF HardTopSeal4DR 14 55397058AF__ Hard Top Seal 2DR___ 14 68004562AB Freedom Panel Latch 11 22 JK Freedom Top Center Front Water Leak Repair 1 Windshield header seal 2 Windshield to cowl seal 3 Front door weatherseal 4 B pillar mucket 5 Hard top seal 6 Center freedom panel seal Outside View 10 14 2008 2 10 14 2008 Rta Gils 7 Left Freedom Panel 8 Panel to Panel Latches 9 Panel to Hard Top Latches 10 Hard Top 11 Right Freedom Panel 12 Latch amp Base Assembly 68004562AB 13 Sport Bar Thumb Screws Please note This package addresses water leaks that come from inside the vehicle when the door is closed This package does not address wa
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