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Jeep Wrangler Diagnosis & Repair Manual Water Leaks

1. SERVICE Stick with the Specialists 23 025 08 2 2 Visually inspect door to windshield frame A Pillar fit Door should be parallel to A Pillar and surface flush to slightly under flush NOTE Vehicles equipped with Freedom Top panels must have the panels CORRECTLY installed This is very important to prevent a water leak from occurring Make sure the technician and customer know and use the correct removal and installation procedure Follow the removal and installation steps in the Owners Manual N O A ND 1 Fig 1 HARD TOP INSIDE FULL VIEW Left Freedom Top Panel Center L Shaped Locks Left Freedom Top Panel Rear L Shaped Lock at Seat Belt Anchorage Left and Right Freedom Top Panel Hard Top B Pillar Right Freedom Top Panel Rear Fastener Dial Knobs Left and Right Freedom Top Panel Windshield Header Latch Left and Right Freedom Top Panel Inspect the Freedom Top panels to ensure that they are installed correctly Fig 1 If not then note this condition so that the correct procedure for installing the Freedom Top panels to the hard top can be reviewed with the customer To ensure that the panels are installed correctly perform the following steps in order When installing each Freedom Top panel always close the windshield latch first a With both panels removed carefully install the right side panel onto the hard top b Make sure the sun visor is fol
2. 9 Generally a car wash is the preferred method to diagnose a vehicle 10 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 NN Area of leaks 11 Table of Contents I Diagnosis Road Map i Il General Notes ii 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 VII Appendix a Foam Kit 21 b Replacement part nu
3. 9mm x 100mm x 6 35mm thick Front Outboard Corner Windshield Header Latch Front Side Surface Right Freedom Top Panel to Windshield Header Panel and Header Seal Front Inboard Corner Front Molded Detail Section of Center Seal and Gray Foam Patch C 5166 30mm x 75mm x 2mm thick Inboard Side Surface Right Freedom Top Panel with Center Seal Rear Inboard Corner Rear Molded Detail Section of Center Seal and Black Foam Patch D 1011 A 30mm x 75mm x 3mm thick 0 N O oa A PD Spacer Blocker and Rear Thumb Dial Screw Attachment i O Rear Side Surface Right Freedom Top Panel to Hard Top and Hard Top Seal Rear L Shaped Lock at Shoulder Belt Anchorage NO Isolator Pad Black Plastic oO Rear Outboard Corner Black Foam Corner Patch D 972 E and Black Foam Patch D 1009 A 20mm x 95mm x 5mm thick i a Oc A Right Freedom Top Panel O Locator Pin Diameter Sizes of 6 0 mm 8 0 mm or 9 5 mm NI Outboard Side Surface Right Freedom Top Panel to Door Seal A Pillar Cup and B Pillar Cup and Mucket Fig 5 REMOVE OLD CENTER SEAL AND BUTYL 1 Old Center Seal 2 Right Freedom Top Panel 3 Old Butyl Adhesive All Old Adhesive Sealants Oil Debris Must Be Removed Cleaned From Panel 3 Remove the old center seal from the right Freedom Top panel Fig 5 23 020 08 Fig 6 REMOVE ALL OLD BUTYL 1 Right Freedom Top Panel 2 Old
4. Jeep Wrangler Diagnosis amp Hepair 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 aleak 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 field
5. Make sure the sun visor is folded down and out of the way 19 23 020 08 c Latch the right header panel latch located at the top of the windshield d Turn the right side panel rear L shaped lock located above the shoulder belt anchorage so that it fully engages the hard top Turn the right side panel rear fastener knob located on the overhead speaker bar assembly clockwise until it is tight Carefully install the left side panel onto the hard top Make sure the sun visor is folded down and out of the way Latch the left header panel latch located at the top of the windshield Turn the left side panel rear L shaped lock located above the shoulder belt anchorage so that it full engages the hard top Turn the left side panel rear fastener knob located on the overhead speaker bar assembly clockwise until it is tight Turn both center L shaped locks 2 so that they fully engage the right side panel 69 Retest to verify that the leak was corrected D Mee pi o SR 23 020 08 20 POLICY Reimbursable within the provisions of the warranty TIME ALLOWANCE 23 51 41 90 Center Seal Modular Top Water Leak A T Hrs Replace B FAILURE CODE NUMBER 23 025 08 sui SERVICE ME BULLETIN pui m 26 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23 016 08 DATED May 24 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLI
6. Turn the left panel rear L shaped lock located above the shoulder belt anchorage so that it disengages from the hard top d Turn the left panel rear fastener knob located on the overhead speaker bar assembly counter clockwise until it can be removed e Unlatch the left panel header panel latch located at the top of the windshield f Carefully remove the left side panel from the hard top g Turn the right panel rear L shaped lock located above the shoulder belt anchorage so that it disengages from the hard top h Turn the right panel rear fastener knob located on the overhead speaker bar assembly counter clockwise until it can be removed Unlatch the right panel header panel latch located at the top of the windshield Carefully remove the right side panel from the hard top J 2 Set the Freedom Top panels on a well PROTECTED WORK SURFACE Protect the Freedom Top panel edges amp top surface from damage NOTE THE PAINTED TOP SURFACE OF THE FREEDOM TOP CAN EASILY BE DAMAGED IF CARE IS NOT TAKEN TO PROTECT IT 3 Verify Freedom Top has been updated with all of the proper foam and butyl parts as shown in SB 23 020 08 Dated June 20 2008 Fig 2 shows placement of these components If SB 23 020 08 has not been completed and leaks are occurring at the windshield header the Freedom Tops will require resealing in conjunction with the header seal replacement Perform SB 23 020 08 before proceeding with this bulletin
7. the front or rear door primary seal to seal against d ste RO 12 c Ju PO cma S VN FA ar DAN POR i V uh x Doors pews ter 4 07 Wrangler Water Leak Repair Water path at missing or off location foam tape on windshield frame shown in correct location Windshield Cowl Seal end detail must not be folded or distorted or a leak can result Doors 07 Wrangler Water Leak Repair Water leak can occur if door check strap trapped in seal 07 Wrangler Water Leak Repair ee CT e 7 aaa Lana a See n c9 LJ Doors Transition foam on soft top rail at rear door B pillar to be between 1mm 3mm 10 Th TM Mah Nae ACA TN VAM NM WA jen ANT V t ea foam Im are presen or module lips Ing Doors W Sn fn Su O O O Sn D O 0 C m C on p D uu CO z Check module fasteners perimeter seal NUMBER 23 002 08 mal SERVICE b BULLETIN sonar is 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23 041 07 DATED SEPTEMBER 29 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH ASTERISKS AND INCLUDE THE ADDITION OF 2007 MODEL YEAR VEHICLES SUBJECT Soft Top Water Leak At Upper A Pillar Door Seal To Door Rail Interface OVERVIEW This bulletin involves the
8. 9 23 025 08 82001 1b3 Fig 2 RIGHT FREEDOM PANEL COMPONENTS 1 Black Foam Corner Patch D 972 E and Black Foam Patch D 1010 A 30mm x 95mm x 3mm thick 2 Gray Foam Strip D 1012 9mm x 100mm x 6 35mm thick 3 Front Outboard Corner 4 Windshield Header Latch 5 Front Side Surface Right Freedom Top Panel to Windshield Header Panel and Header Seal 6 Front Inboard Corner Front Molded Detail Section of Center Seal and Gray Foam Patch C 5166 30mm x 75mm x 2mm thick 7 Inboard Side Surface Right Freedom Top Panel with Center Seal 8 Rear Inboard Corner Rear Molded Detail Section of Center Seal and Black Foam Patch D 1011 A 30mm x 75mm x 3mm thick 9 Spacer Blocker and Rear Thumb Dial Screw Attachment 10 Rear Side Surface Right Freedom Top Panel to Hard Top and Hard Top Seal 11 Rear L Shaped Lock at Shoulder Belt Anchorage 12 Isolator Pad Black Plastic 13 Rear Outboard Corner 14 Black Foam Corner Patch D 972 E and Black Foam Patch D 1009 A 20mm x 95mm x 5mm thick 15 Right Freedom Top Panel 16 Locator Pin Diameter Sizes of 6 0 mm 8 0 mm or 9 5 mm 17 Outboard Side Surface Right Freedom Top Panel to Door Seal A Pillar Cup and B Pillar Cup and Mucket NOTE Vehicles equipped
9. Butyl Adhesive In Front and Rear Inboard Corner Notches All Old Adhesive Sealants Oil Debris MUST Be Removed and Cleaned From Panel 4 Clean ALL old butyl adhesive from the Freedom Top panel center seal surface inboard corners and notches Wipe the panel surface clean where the new seal will attach with a high quality adhesive remover Fig 6 5 Using a Scotch Bite pad rough up the right panel surface where the center seal will make contact Remove all residue with alcohol Allow to dry completely NOTE ALL old adhesive sealant oils debris MUST BE thoroughly removed from the Freedom Top panel surface and inboard corner notches Use a high quality adhesive remover and a small pick to remove the remaining old adhesive Once the old adhesive has been removed thoroughly clean and prep the entire surface for the new seal by removing any residual adhesive and oils with the high quality adhesive remover Fig 7 CENTER SEAL SECTIONS 1 Front Molded Detail Section 2 Middle Extruded Section 3 Rear Molded Detail Section The new center seal is made up of three sections a 70 mm long front molded detail section a long middle extruded section and a 70 mm long rear molded detail Fig 7 Both front and rear molded details have adhesive backing tape The technician will need to add NEW butyl adhesive to the front and rear inboard corner notches to further assist with attaching the details to the panel and to prevent a water leak path T
10. INSTALLED 1 Middle Section Firmly Pressed In Place Center Seal 2 Front Molded Detail Section Center Seal 3 Gray Foam Patch with Adhesive Promoter Already Applied Flush To Edges Of Flame Tip Front Molded Detail 4 Correct Front Molded Detail Seal Contact To Right Freedom Top Panel 23 020 08 14 Rear Molded Detail Section Install Final Steps 33 Make sure the rear molded detail contact with the panel is correct Fig 19 Fig 19 SEAL POSITION AT MOLDED DETAIL GOOD BOTTOM EDGE OF MOLDED DETAIL TO COVER LIP ON FREEDOM PANEL REAR MOLDED DETAIL FREEDOM PANEL BAD BOTTOM EDGE OF MOLDED DETAIL IS TUCKED BEHIND LIP ON FREEDOM PANEL gt c N 34 Add adhesive promoter to the surface of the rear molded detail flame tip area where the black foam will be attached to the seal Allow the adhesive promoter to dry completely 35 Add a 30 mm x 75 mm BLACK foam patch from the Replacement Foam Kit to the under side of the panel covering the flame tip of the rear molded detail of the center seal Make certain the corners and edge of the foam patch align with the outside edges of the flame tip Fig 20 Fig 20 ADD BLACK FOAM PATCH TO DETAIL 1 Rear Molded Detail Section 2 Adhesive Promoter Apply To Flame Tip Rubber And Allow To Dry Then Install Black Foam Patch Rear Molded Detail 36 Press the 30 mm x 75 mm BLACK foam patch to panel Fig 21 Fig 21 PRESS FOAM PATCH INTO PLACE 1 Rear Inbo
11. at Seat Belt Anchorage Left and Right Freedom Top Panel 4 Hard Top 5 B Pillar 6 Right Freedom Top Panel 7 Rear Fastener Dial Knobs Left and Right Freedom Top Panel 8 Windshield Header Latch Left and Right Freedom Top Panel 3 23 020 08 Inspect the Freedom Top panels to ensure that they are installed correctly Fig 1 If not then note this condition so that the correct procedure for installing the Freedom Top panels to the hard top can be reviewed with the customer To ensure that the panels are installed correctly perform the following steps in order When installing each Freedom Top panel always close the windshield latch first a With both panels removed carefully install the right side panel onto the hard top b Make sure the sun visor is folded down and out of the way c Latch the right header panel latch located at the top of the windshield d Turn the right side panel rear L shaped lock located above the shoulder belt anchorage so that it fully engages the hard top Turn the right side panel rear fastener knob located on the overhead speaker bar assembly clockwise until it is tight Carefully install the left side panel onto the hard top Make sure the sun visor is folded down and out of the way Latch the left header panel latch located at the top of the windshield Turn the left side panel rear L shaped lock located above the shoulder belt anchorage so that it full engages the hard top Turn t
12. be used to smooth tape and butyl 13 Ensure the butyl is feathered out smooth and adhesive tape is pressed to make full contact Work back and forth from side to side 23 025 08 14 Install the Freedom Panels to the hard top To ensure that the panels are installed correctly perform the following steps in order When installing each Freedom Panel always close the windshield latch first Make sure the sun visors is folded down and out of the way b Carefully install the right side panel onto the hard top c Latch the right header panel latch located at the top of the windshield d Turn the right side panel rear L shaped lock located above the shoulder belt anchorage so that it fully engages the hard top Turn the right side panel rear fastener knob located on the overhead speaker bar assembly clockwise until it is tight f Carefully install the left side panel onto the hard top g Latch the left header panel latch located at the top of the windshield h Turn the left side panel rear L shaped lock located above the shoulder belt anchorage so that it full engages the hard top i Turn the left side panel rear fastener knob located on the overhead speaker bar assembly clockwise until it is tight j Turn both center L shaped locks 2 so that they fully engage the right side panel 15 Retest to verify that the leak was corrected POLICY Reimbursable within the provisions of the warranty sa D TIME
13. closed This package does not address water that drips into the Vehicle when the door is open This is a normal condition 10 14 2008 2 1 Windshield header seal 2 Windshield to cowl seal 3 Front door weatherseal 4 B pillar mucket 5 Hard top seal Outside View 6 Center freedom panel seal 10 14 2008 3 Check door fit e The door gap spec is 5 1 5 mm Door Must be Flush to slightly under flush to A Pillar E i E cu Adjust door Gap AND Flushness as described in Body Section 23 of the Service Manual 10 14 2008 Header Weather Strip Remove Header Weather Strip from Body sheet metal and clean up remove all traces of old Tape and Butyl from painted sheet metal surfaces before reinstallation of butyl bead and new weather strip Clean Seal Surface with 3M General Purpose Adhesive Cleaner or Kent Products Acrysol if available and allow to dry completely Weather Strip Removal amp Butyl Clean Up 10 14 2008 Weather Strip Removal amp Butyl Clean Up N e entire me Clean up remove all traces of old Tape and Butyl from painted sheet metal surfaces Alcohol wipe the clean sheet metal before installation of butyl bead and new weather strip 10 14 2008 Header Weather Strip Butyl Placement and New Weather Strip Installation Right Side Shown on Pages 8 9 amp 10 Left Side Not Shown but symmetrical identical to Right 10 14 2008 7 Fil
14. of the areas described in this step then refer to the DealerCONNECT file Water leaks at the upper A pillar that drip onto the outboard ends of the instrument panel is an indicator of a water leak path between the door inner panel or seal and the Freedom Top panel interface and or the windshield header seal There also could be a water leak path at the radius of windshield header area If a water leak is in one of these areas then this Service Bulletin does not apply Refer to the DealerCONNECT A Pillar file Water leaks at the upper B Pillar outboard of the sport bar that drip onto the B Pillar hard trim panel is an indicator of a water leak path between the hard top and the Freedom Top panel or a water leak path under the hard top seal If a water leak is in this area then this Service Bulletin does not apply Refer to the DealerCONNECT file Water leaks at the upper B Pillar outboard of the sport bar that drip onto the inner surface of the door panel at the B Pillar is an indicator of a water leak path between the door inner panel or seal and the Freedom Top panel interface If a water leak is in this area then this Service Bulletin does not apply Refer to the DealerCONNECT file 23 020 08 4 PARTS REQUIRED AR 1 68026937AB Kit Replacement Foam AR 1 55397095AG Seal Targa Top Right Freedom Top Panel Center DO NOT use previous versions of this seal AR 2 68004562AB Latch Targa Panel Header AR 1 NPN Adhesive Remover or Equiv
15. while the left panel is being worked on Later both panels will need to have their outboard corners inspected and repaired 23 020 08 16 Left Freedom Top Panel Fig 24 ADD BUTYL TO REAR INSIDE CORNER Rear Inboard Corner Left Freedom Top Panel Hard Top Side Rear Surface Left Freedom Top Panel Install 100 mm Of New Butyl Adhesive 4 mm dia Into Groove At Edge Of Panel Butyl To Be Flush To Top Of Groove Install 70 mm Of New Butyl Adhesive 4 mm dia Into At Edge Of Panel Butyl To Be Flush To Top Of Groove a A c N Center Seal Side Surface Left Freedom Top Panel 40 Move to the left Freedom Top panel Locate the inboard rear corner of the left panel 41 Clean ALL old butyl adhesive from the left panel inboard rear corner surface notches and grooves Wipe the panel rear inboard corner surface clean with a high quality adhesive remover NOTE ALL old adhesive sealant oils debris MUST BE thoroughly removed from the panel surface and rear inboard corner notches groove Use the high quality adhesive remover and a small pick to remove the remaining old adhesive Once the old adhesive has been removed thoroughly clean and prep the entire rear inboard corner surface by removing any residual adhesive and oils with the high quality adhesive remover 42 Add new butyl adhesive 4 mm in diameter into the inboard rear corner outer groove of the left panel Fig 24 Apply the new butyl adhesive for 70 mm int
16. 6 Verify that the alignment pin is in place and not damaged Replace the alignment pin if damaged or missing Dependent upon when the hard top panel was made there are different size alignment pins Install the correct size diameter alignment pin 57 Place the left panel to the side on a protected surface 58 Place the RIGHT PANEL top facing down on the protected work surface 23 020 08 18 59 Repeat the above step in this section Outboard Corners Both Freedom Top Panel to the front and rear outboard corners Install Windshield Header Seal Stuffer Fig 28 WINDSHIELD STUFFER LOCATION 1 Bulb Where Rubber Stuffer Will Be Installed Under Windshield Header Seal 2 Rubber Stuffer 13 mm OD x 8 mm ID x 160 mm Install and Center Under Windshield Header Seal Bulb 3 Make A Smooth 30 mm Cut Along Seam At Bottom Of Bulb Install Rubber Stuffer Through Cut Opening 60 Move to the windshield header seal 61 Locate the windshield header seal round stuffer C 5165 13mm OD x 8mm ID x 160mm from the Replacement Foam Kit 62 Place the windshield header seal round stuffer to the windshield header seal bulb Center the stuffer to the center of the windshield header seal Fig 28 Temporarily place a mark on the windshield center seal at each end of the stuffer If a stuffer is already in place then it will be replaced with this new stuffer 63 Using a razor blade a cut will be made into the windshield header seal bulb to allow pl
17. ALLOWANCE 23 51 35 97 Seal Modular Top to Header Replace due 1 2 Hrs to A Pillar Water Leak B FAILURE CODE NUMBER 23 005 09 REV A EY SERVICE GROUP Body BULLE TIN DATE August 12 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 23 002 08 DATED JANUARY 15 2008 23 020 08 DATED JUNE 20 2008 23 025 08 DATED AUGUST 26 2008 AND 23 005 09 DATED MARCH 24 2009 WHICH SHOULD BE REMOVED FROM YOUR FILES THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT Hard Top Soft Top Water Leak Diagnosis OVERVIEW This bulletin introduces a New Water Leak Repair Manual that should be followed whenever a vehicle is brought in with water leak concerns MODELS 2007 2009 JK Wrangler NOTE This bulletin applies to vehicles equipped with a soft top dual top and targa top sales code GWK VJ0 AEM and VJX SYMPTOM CONDITION Water leaks from hard or soft top and water on the carpet DIAGNOSIS A new approach to addressing water leak concerns on Wrangler models has been developed and is announced with this Service Bulletin The New Manual can be accessed through DealerCONNECT gt Efiles The file is found in the Service section gt STAR Center Misc Documents JK Water Leak Repair Manual The manual provides detailed color graphics and instructions to address many of the leak concerns associated with the Soft or Hard top models The manual is broken out by
18. EAR DETAIL INTO PLACE Release Tab Adhesive Backing Tape New Butyl Adhesive 4 mm Diameter Rear Inboard Corner and Notch Right Freedom Top Panel Center Seal Surface Side Right Freedom Top Panel Center Seal A W m Rear Molded Detail Section Firmly Press Into Place Remove Any Excess proud Butyl Adhesive Replace Right Panel Header Latch 20 If vehicle was built prior to December 17 2007 MDH 1217XX then replace the right panel header latch Fig 1 11 23 020 08 Attach Middle Section of the Center Seal DN Co N 21 22 23 24 25 Fig 12 MIDDLE SECTION OF CENTER SEAL Right Freedom Top Panel Middle Section Center Seal Still Unattached Until Now Fig 13 CENTER SEAL CROSS SECTION New Center Seal Cross Section Right Freedom Top Panel Center Seal Channel and Panel Indexing Ridge With both front and rear molded detail sections attached move to the middle section of the center seal Note that at this point that both ends front and rear molded details of the center seal are attached but the middle section of the center seal is not yet attached Fig 12 Note how the middle section of the center seal will engage the alignment ridge on the panel Fig 13 Carefully turn right panel over so that the top painted surface is facing up When installing the middle section of the center seal take care not to allow the middle section of the seal to bunch
19. GHT REVISIONS SUBJECT Freedom Top Header Seal Water Leak In Area Of Dash OVERVIEW This bulletin involves the replacement of the header seal and its associated butyl adhesive MODELS 2007 2008 JK Wrangler NOTE This bulletin applies to vehicles equipped with a Freedom Modular Hard Top Sales code VKO Vehicles equipped with Dual Tops Soft Top and Freedom Top should have this bulletin performed with the Freedom Top installed only NOT THE SOFT TOP The replacement header seal may initially cause a soft top wind noise SYMPTOM CONDITION This bulletin will address water leaks due to the FRONT HEADER SEAL at the roof Water leaks associated with the header seal can cause the front floor and or instrument panel to get wet Water leaking into the vehicle at the B Pillar or anywhere further back in the vehicle are not covered in this Service Bulletin Water leaks in these areas are addressed in other Service Bulletins and eFiles Refer to those Service Bulletins and eFiles as necessary NOTE Refer to additional supporting material and pictures available in DealerCONNECT and TechCONNECT Select eFiles gt Service gt Star Center gt Misc Documents JK A Pillar Water Leak Repair DIAGNOSIS 1 Determine the vehicle build date Vehicles equipped with a Freedom Modular Hard Top and built on or before December 17 2007 MDH1217XX will require the windshield header latch on each panel be replaced with the latest level latch
20. OTE This repair applies 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 STEP2 Heplace the mucket detail If either of these conditions exist replace the mucket detail Fi a8 Part 55395708 9AE pH 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 68026937 AB RH Panel Shown Figure 40 STEP4 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 rom E i PAL e Ta LIA i NET 3 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 Heplace Install Patch Hole o NOTE Veh
21. RTANT Verify full adhesion of the entire new center seal to the Freedom Top panel THS IS CRITICAL Front Molded Detail Section Install Final Steps 30 31 c N N Add adhesive promoter to the surface of the front molded detail flame tip area where the gray foam will be attached to the seal Allow the adhesive promoter to dry completely To the front molded detail add a 30 mm x 75 mm hard GRAY foam patch Fig 16 from the Replacement Foam Kit to the underside of the panel covering the flame tip of the D shaped bulb Fig 17 Fig 16 ADD A GRAY FOAM PATCH TO DETAIL Adhesive Promoter Apply To Flame Tip Rubber And Allow To Dry Then Install Gray Foam Patch New Butyl Adhesive Flush To Right Freedom Top Panel Surface Front Molded Detail Section Center Seal Foam Stuffer 7 mm OD x 71 mm Length Reference Fig 17 PRESS SEAL AND PATCH INTO PLACE Front Inboard Corner And Notch Right Freedom Top Panel Smooth Flat Transition Rubber Tab Front Molded Detail Smooth Flat Transition Pressed In Place Gray Foam Patch with Adhesive Promoter Already Applied 13 23 020 08 32 Once the final steps are completed then inspect the front molded detail section of the center seal for proper installation Fig 18 The gray foam with adhesive promoter should be flush with the corner of the flame tip The front molded detail contact to the panel should be correct Fig 18 FRONT DETAIL CORRECTLY
22. Section Firmly Press Into Place Remove Any Excess proud Butyl Adhesive 12 Align the front molded detail to the front inboard corner of the right Freedom Top panel Fig 10 13 Firmly press the front molded detail of the center seal to the front inboard corner of the panel Verify that the new butyl adhesive is in full contact with the molded detail and is well compressed 14 The butyl adhesive should be flush with the panel bottom surface Remove any excess butyl adhesive that is proud of the panel bottom surface This will help to ensure a smooth transition at the front end of the new center seal 15 Remove the release tape from the front molded detail and firmly press the adhesive tape of the front molded detail to the panel Attach Rear Molded Detail Section of the Center Seal 16 Align the rear molded detail to the rear inboard corner of the right Freedom Top panel 17 Firmly press the rear molded detail of the center seal to the rear inboard corner of the panel Verify that the new butyl adhesive is in full contact with the molded detail and is well compressed 18 The butyl adhesive should be flush with the panel bottom surface Remove any excess butyl adhesive that is proud of the panel bottom surface This will help to ensure a smooth transition at the rear end of the new center seal 19 At the rear molded detail remove the release tape and firmly press the rear molded detail adhesive tape to the panel Fig 11 PRESS R
23. acement of the stuffer inside of the windshield header seal bulb The cut will be made along the bottom edge of the bulb Mark a 30 mm length on the header seal bulb where the cut will be placed 64 Where the right end of the stuffer will end and along the bottom edge of the header seal bulb CAREFULLY place a 30 mm cut through the header seal bulb material 65 CAREFULLY install the stuffer into the windshield header seal Take care not to tear the seal bulb material Use a light water based lubricant to aid installation 66 Glue the stuffer in place Apply glue Mopar Bond All Gel to the stuffer and inside surface of the header seal bulb 67 CAREFULLY glue using Mopar Bond All Gel the cut in the header seal bulb closed Fig 29 WINDSHIELD SEAL CROSS SECTION Panel Interface With The Windshield Header Seal Freedom Top Panel Location Of 30 mm Cut Install Stuffer Through Cut Opening Seal Cut With Glue Rubber Stuffer 13 mm OD x 8 mm ID x 160 mm Installed Inside Windshield Header Seal Bulb Cross Section Windshield Header Seal Windshield Frame a A c N Install Freedom Top Panels and Retest For Water Leaks 68 Install the Freedom Panels to the hard top Fig 1 To ensure that the panels are installed correctly perform the following steps in order When installing each Freedom Panel always close the windshield latch first a With both panels removed carefully install the right side panel onto the hard top b
24. acing up outside surface of panel is resting on the protected work surface At the front inner corner of the panel loose fit do not attach at this time the front molded detail of the new center seal to the front inner corner Note and mark where the front molded detail wraps at the intersecting edges of the front corner This is where new butyl adhesive will need to be applied DO NOT reuse any old butyl adhesive Add NEW butyl adhesive 4 mm dia to the front inner corner of the right Freedom Top panel The butyl adhesive is to run along both intersecting edges of the inner corner Make certain there is sufficient butyl along each intersecting edge of the front corner to fully cover the molded detail Fig 8 Make sure the new butyl adhesive is on the edge and must be in the groove in all areas before the front molded detail is installed Later when the front molded detail is installed and pressed in place the new butyl will migrate into the groove areas Fig 8 FRONT NOTCH BUTYL APPLICATION Windshield Header Surface Side and Guide Right Freedom Top Panel New Butyl Adhesive 4 mm in diameter Apply Per Dimensions Shown Apply Along Outer Edge Push In Place Front Inboard Corner Right Freedom Top Panel Center Seal Side Right Freedom Top Panel 9 23 020 08 Apply New Butyl Adhesive To Panel Rear Inboard Corner 9 10 gt c N Move to the rear inboard corner of the panel and the rear molded detail At th
25. addition of foam to eliminate a possible water leak at the upper A Pillar MODELS 2007 2008 JK Wrangler NOTE This bulletin applies to vehicles equipped with a soft top sales code GWK or VJO or with a dual top sales code AEM SYMPTOM CONDITION On soft top equipped vehicles water may leak past the door seal to door rail interface at the upper A Pillar DIAGNOSIS 1 Verify that the soft top is correctly installed and fastened correctly to the vehicle The soft top cover should be located and clamped in the correct sequence as described in the Owners Manual Apply water to the affected area for about 3 5 minutes while inspecting the interior of the vehicle for possible water leaks and leak source If the source of the water leak is from the interface of the door seal to the door rail at the upper A Pillar then perform the Repair Procedure PARTS REQUIRED PattNo Description 68026937AA Kit Replacement Foam Repair N co Stick with the Specialists 23 002 08 2 REPAIR PROCEDURE 1 Fold back the entire soft top 2 Remove the front left and right plastic door rail frame from the vehicle body 3 Inspect the windshield header seal molded details to ensure that the dark gray foam is present and not damaged The dark gray foam is located at each outer end of the windshield header seal If the dark gray foam is damaged remove the old foam and replace with new dark gray fo
26. alent such as 08984 3M General Purpose Adhesive Cleaner or 20005 Kent Products Acrysol AR 1 04467709 Mopar Bond All Gel or equivalent AR 1 NPN Adhesive Promoter or Equivalent such as 4298 3M Adhesive Promoter inm Alcohol 68046593AA Butyl Tape 60 mm length x 12 mm wide x 2 mm height strip 68027813AA Butyl Tape 4 mm dia x 152 mm 6 inch length strip 68048423AA Butyl Tape 4 mm dia x 1 830 mm 6 ft length roll AR 5 68004991AA Isolator Targa Top Freedom Top Panel Plastic Fig 2 HARD TOP SEALS B Pillar Cup Hard Top Seal Left and Right Side Hard Top Seal Center Cup Hard Top Seal Left Freedom Top Panel Center Seal Right Freedom Top Panel Windshield Header Seal A Pillar Cup Windshield Header Seal Left and Right Side Windshield Cowl Seal Right Freedom Top Panel 10 Door Seal 11 B Pillar Mucket Left and Right Side O N O oa A N 1 2 3 4 5 6 9 23 020 08 Fig 3 REPLACEMENT FOAM KIT Black Foam Corner Patch D 972 E Used At Front and Rear Outboard Corners on RIGHT Freedom Top Panel Black Foam Corner Patch D 973 E Used At Front and Rear Outboard Corners on LEFT Freedom Top Panel Black Foam Patch D 1010 A 30mm x 95mm x 3mm thick Used At Front Outboard Corner Lt and Rt Panels to Header Seal Black Foam Patch D 1011 A 30mm x 75mm x 3mm thick Used At Rear Inboard Corner Left and Right Panels Interface Blac
27. all the soft top in the correct installation sequence as referenced in the Owners Manual 23 002 08 4 81eed9bd Fig 3 BLACK FOAM FULLY SEATED 1 Door Frame Rail Foam 2 New Black Foam Piece From Replacement Foam Kit Fully Seated To Door Frame Rail End And Side 3 Plastic Door Frame Rail POLICY Reimbursable within the provisions of the warranty TIME ALLOWANCE 23 51 35 95 Water Leak Test At A Pillar 0 2 Hrs Inspection B 23 51 35 96 Water Leak Test and Additional 0 9 Hrs Foam Install To Soft Top Door Rails B FAILURE CODE NUMBER 23 020 08 c SERVICE d BULLETIN pen 20 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 23 001 07 DATED JANUARY 06 2007 AND 23 050 07 DATED NOVEMBER 21 2007 THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT Freedom Top Center Seal Water Leak In Area Of Center Console or Dash OVERVIEW This bulletin involves the select replacement of the center seal and its associated foam tape butyl adhesive and weatherstrips MODELS 2007 2008 JK Wrangler NOTE This bulletin applies to vehicles equipped with a Freedom Top Modular Hard Top SYMPTOM CONDITION On vehicles equipped with a Freedom Top a leak water may occur in the area of the hard top removable targa panels This bulletin will address water leaks due to the CENTER SEAL of the removable Freedom Top targa panel If the center seal is
28. am from the Replacement Foam Repair Kit Fig 1 81eed9b1 Fig 1 DARK GRAY FOAM HEADER SEAL 1 Dark Gray Foam At End Of Header Seal Right Side Of Windshield Frame Shown 2 Windshield Header Seal 3 Windshield Frame Upper A Pillar Right Side NOTE The Replacement Foam Repair Kit includes all foam pieces for the vehicle Not all foam pieces in the kit will be required for this Repair Procedure 4 Obtain the black foam piece from the Replacement Foam Repair Kit The black foam pieces are handed one for the left side and one the right side Select the correct side black foam piece 5 Temporarily line up loose fit the perimeter of the black foam piece to the front edge of the door rail Fig 2 3 23 002 08 81eed9bc Fig 2 BLACK FOAM LOOSE FIT 1 Door Frame Rail Foam 2 New Black Foam One Piece Left Handed and One Piece Right Handed Loose Fit To Door Frame Rail 3 Plastic Door Frame Rail Leading End Edge Removed From Vehicle To Effect Repair 6 Remove the white protective backing from the black foam piece and attach the black foam to the door rail 7 Wrap the black foam around the front edge of the door rail Fig 3 8 Complete the installation of the black foam the to door rail by wrapping the foam onto the underside of the door rail 9 Repeat the above procedure for the opposite side 10 Raise and install the soft top to the vehicle It is important to inst
29. anel Water Leaks on Freedom Panels as on Windshield Header per Fig 7 one on the Seal as per Fig 3 Foam Kit includes the following foam pieces left panel and one on the right Foam to be installed on right Freedom Panel as per Fig 6 Both pieces to be installed on Freedom Panels as per Fig 4 one on the left panel and one on the right All four pieces two right and two left to be installed on Freedom Panels as per Fig 4 one left and one right to be 3 Wo SERE TES installed on door rails Both pieces to be e Li EE as per Fig 1 amp 2 installed on Freedom EEUU QUAS LL puc 1 ACIES SIE edge P Panels as per Fig 5 one on the left panel and one on the right Foam to be installed on right Freedom Panel as per Fig 8 Page of 5 Reference Foam Locations on Vehicle Soft Tops Figure 1 Rough Position of Foam on Right Door Rail Reference location 1 on both left and right sides of vehicle 1 Door frame rail foam 2 New black foam highlighted foam One piece left handed and one piece right handed Loose fit to door frame rail 3 Plastic door frame rail Leading end edge removed from vehicle to affect repair Figure 2 Black Foam Fully Seated Note Ensure that header seal 1s not pinched under foam when re installing the door rail Page 2 of 5 Reference Foam Locations on Vehicle Hard To Fro
30. anel 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 lt a A Figure 31 Labor Op Code B Pillar Mucket Foam Seal Repair STEP 1 Inspect Hard Top Seal cont e Inspect the end molds for poor installation Figure 32 A ib d M Mis ELE DSi mou rwmm Pe Bx BAD GAP Figure 32 Tr GOOD GAP Figure 33 Labor Op Code Inspect underneath the seal for any skips with the tape butyl along the entire seal Figure 34 amp 35 Figure 35 13 B Pillar Mucket Foam Seal Repair STEP2 Heplace 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 L unaeriius 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 plrtrim or seat N
31. ard Corner and Notch Right Freedom Top Panel 2 Black Foam Patch With Adhesive Promoter Press Firmly In Place 3 Black Foam Patch Flush With Edges Of Rear Molded Detail 15 23 020 08 3 Using a SHARP razor blade carefully trim off the outer corner of the foam so that is conforms to the flame tip of the rear molded detail of the center seal Fig 22 Fig 22 TRIM OFF CORNER OF BLACK PATCH 1 Remove Excess Foam Trim To Edge Of Molded Detail Black Foam Patch NM Rear Molded Detail Section Center Seal Right Freedom Top Panel Middle Section Center Seal Right Freedom Top Panel Fig 23 REAR MOLDED DETAIL FLAME TIP Flame Tip Rear Molded Detail Section Center Seal Black Foam Patch With Adhesive Promoter Applied Flush With Edges Of Flame Tip Remove Excess Foam Trim To Edge Of Molded Detail Black Foam Patch 1 2 3 4 Rear Molded Detail Section Center Seal 5 Middle Section Center Seal 7 Notch in Rear Molded Detail Section 5 mm x 15 mm Reference 8 Correct Rear Molded Detail Seal Contact To Right Freedom Top Panel 38 Once the final steps are completed then inspect the rear molded detail section of the center seal for proper installation Fig 23 The black foam with adhesive promoter applied should be flush with the corner of the flame tip The rear molded detail contact to the panel should be correct 39 Move the right panel off to the side onto a protected surface
32. at fault the customer may experience a water leak in one of the following areas a On to the center console b On to the center section of the instrument panel c From the Freedom panel knob dial fasteners d At the sports bar cloth covering inboard of the B Pillar e On to the front seat cushion or seat back Water leaks may occur in other areas of the vehicle body that interface with the Freedom Top panels These other areas may include the A Pillar the B Pillar or the Door Water leaks in these areas are addressed in other Service Bulletins Refer to those Service Bulletins as necessary 23 020 08 2 DIAGNOSIS 1 Prior to performing this Service Bulletin refer to additional supporting material found in Dealer CONNECT and TechCONNECT At DealerCONNECT select eFiles Service at left side of page Star Center Misc Documents 2 Determine the vehicle build date Vehicles built on or before December 17 2007 MDH 1217XX will require the windshield header latch on each panel be replaced with the latest level latch NOTE Installing the Freedom Top panels CORRECTLY is very important to prevent a water leak from occurring Make sure the technician and customer know and use the correct installation and removal procedure Follow the removal and installation steps in the correct order Fig 1 HARD TOP INSIDE FULL VIEW 1 Left Freedom Top Panel 2 Center L Shaped Locks Left Freedom Top Panel 3 Rear L Shaped Lock
33. butyl firmly in place Labor Op Code 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 Locate seal cross car against the middle rib in the freedom panel and pressurize starting at the ends and working toward the center e Asmall 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 rib STEP 6 Install foam at Front e Install GREY 30 X 75 mm Foam from k
34. ded down and out of the way c Latch the right header panel latch located at the top of the windshield 3 23 025 08 d Turn the right side panel rear L shaped lock located above the shoulder belt anchorage so that it fully engages the hard top Turn the right side panel rear fastener knob located on the overhead speaker bar assembly clockwise until it is tight Carefully install the left side panel onto the hard top Make sure the sun visor is folded down and out of the way Latch the left header panel latch located at the top of the windshield Turn the left side panel rear L shaped lock located above the shoulder belt anchorage so that it full engages the hard top j Turn the left side panel rear fastener knob located on the overhead speaker bar assembly clockwise until it is tight Turn both center L shaped locks 2 so that they fully engage the right side panel 4 Only after verifying Freedom Top is properly installed Proceed to Test For Water Leak s Test For Water Leak s 1 Have an assistant apply a slow flow of water across the top header joint with a hose for approximately 3 5 minutes while inspecting the interior of the hard top for water leaks to determine general leak source location s Do not use a hard spray of water Do not stop inspection when one leak source is located there may be more than one water leak source D Ee ni a NOTE Dripping that occurs at the center of the windshield heade
35. e rear inner corner of the panel loose fit the rear molded detail of the new center seal to the rear inner corner Note and mark where the rear molded detail wraps at the intersecting edges of the rear corner This is where new butyl adhesive will need to be applied Do not reuse any old butyl adhesive Add NEW butyl adhesive 4 mm in dia to the rear inner corner of the right Freedom Top panel The butyl adhesive is to run along both intersecting edges of the rear inner corner Make certain there is sufficient new butyl along each intersecting edge of the rear corner to fully cover the molded detail Make sure the new butyl adhesive is on the edge and must be in the groove in all areas before the rear molded detail is installed Later when the rear molded detail is installed and pressed in place the new butyl will migrate into the groove areas Fig 9 REAR NOTCH BUTYL APPLICATION Hard Top Surface Side Right Freedom Top Panel Center Seal Surface Side Right Freedom Top Panel New Butyl Adhesive 4 mm in Diameter Apply Per Dimensions Shown Apply Along Outer Edge Push In Place Rear Inboard Corner and Notch Right Freedom Top Panel 23 020 08 10 Attach Front Molded Detail Section of the Center Seal Fig 10 PRESS FRONT DETAIL INTO PLACE 1 Center Seal Surface Side Right Freedom Top Panel 2 Front Inboard Corner Right Freedom Top Panel 3 Flame Tip Front Molded Detail Section 4 Front Molded Detail
36. gure 4 Line seal up here 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 A e The flush spec is 0 0 2 0 mm e Ifthe door fit is not to spec proceed to Step 2 STEP2 Adjust Doors e Adjust the door gap and flushness as described in DealerConnect TechCONNECT under Service info 23 Body Body Structure Gap and Figure 6 Flush 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 9 4 A Pillar Foam Mucket Repair Procedure STEP 2 A Pillar Foam e NOTE This issue repair applies
37. he left side panel rear fastener knob located on the overhead speaker bar assembly clockwise until it is tight Turn both center L shaped locks 2 so that they fully engage the right side panel D gt Have an assistant apply a slow flow of water across the hard top Freedom Top panel joints with a hose for approximately 3 5 minutes while inspecting the interior of the hard top for water leaks to determine general leak source location s Do not use a hard spray of water Do not stop inspection when one leak source is located there may be more than one water leak source Water leaks at the front of the vehicle onto the center section of the instrument panel IP and or onto the center console area are indicators of a front center seal Freedom Top panel leak path The water leak could be a rear center seal Freedom Top panel leak that travels forward Water leaks could also be a result of poor contact between the windshield header weatherstrip seal and the Freedom Top panel center seal If a water leak is in one or more of the areas described in this step then perform the Repair Procedure in this Service Bulletin and refer to the DealerCONNECT file Water leaks from Freedom Top panel knob dial fasteners in speaker bar leaks near the left or right B Pillar onto sport bar cloth covering or onto front seats are indicators of a water leak path from the rear section of the Freedom Top panel center seal If a water leak is in one of more
38. he middle extruded section of the center seal comes with NEW butyl adhesive that is protected by backing tape prior to installation When the new center seal is installed to the Freedom Top panel the technician will need to ensure that all three sections of the center seal are firmly affixed by their adhesives to the panel that there are no water leak paths and that the front and rear molded details make a gradual and smooth transition when they mate to the windshield header seal at the front and to the hard top seal at the rear To install a new center seal the front and rear sections are attached to the right Freedom Top panel first followed by the installation of the center section of the seal to the panel The front and rear molded detail sections must be firmly in place and must not move out of place when the middle section of the center seal is installed To accomplish this the middle section of the center seal is attached to the panel starting at the ends of the seal and working toward the center of seal Care must be taken to make sure that the front and real molded ends of the seal do not move yet making sure that the middle section of the 23 020 08 8 seal is not bunched up at the center when it is installed Apply New Butyl Adhesive To Panel Front Inboard Corner 6 c N On the right Freedom Top panel locate the front inboard corner Turn the right Freedom Top panel over so that the inside surface of the panel is f
39. icles 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 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 Labor Op Code Leak Path mm Figure 42 y 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 44 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 Apply hose in cowl area Figure 47 Cowl Side Panel Repair Condition 1 Mastic patches Plugs 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 s
40. it 68026937AB along trim lines of flame tip Figure 24 e NOTE Make sure foam covers butyl completely Labor Op Code m A j 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 Si Figure 26 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 Figure 28 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 pillar roll bar o B pillar trim o Freedom p
41. k Foam Patch D 1009 A 20mm x 95mm x 5mm thick Used At Rear Outboard Corner Lt And Rt Panels to Hard Top Seal Center Seal End Molded Detail Round Stuffer C 5164 7mm OD x 72mm Used At Frt and Rr Molded Detail Sections of Center Seal 4 Windshield Header Seal Round Stuffer C 5165 13mm OD x 8mm ID x 160mm Used At Placed Inside Windshield Header Seal Bulb 8 9 Gray Foam Patch C 5166 30mm x 75mm x 2mm thick Used At On Flame Tip of Front Molded Detail Section of Center Seal Gray Foam Strip D 1012 9mm x 100mm x 6 35mm thick Used At Front Outboard Corner Lt and Rt Panels to Header Seal REPAIR PROCEDURE NOTE Do not use RTV as a sealer Over time RTV will not remain attached to the hard top material NOTE If seal requires replacement then the old seal adhesive must be completely removed before a new seal is installed Use a GOOD quality adhesive remover as recommended in Parts Required section of this Service Bulletin NOTE All steps must be followed in order and completed fully Do not omit any steps Make sure the correct adhesive remover cleaner alcohol adhesive promoter new butyl replacement foam kit and center seal are available prior to proceeding with this repair Make sure the paint surfaces of the panels will be well protected to prevent scratches or other damage Hemove both Freedom Top Panels from the hard top Fig 1 Perform the following steps in order a At the left panel ma
42. ke sure the left sun visor is folded down and out of the way b Turn both left panel center L shaped locks 2 so that they disengage from the right side panel c Turn the left panel rear L shaped lock located above the shoulder belt anchorage so that it disengages from the hard top d Turn the left panel rear fastener knob located on the overhead speaker bar assembly counter clockwise until it can be removed Unlatch the left panel header panel latch located at the top of the windshield Carefully remove the left side panel from the hard top At the right panel make sure the right sun visor is folded down and out of the way Turn the right panel rear L shaped lock located above the shoulder belt anchorage so that it disengages from the hard top Turn the right panel rear fastener knob located on the overhead speaker bar assembly counter clockwise until it can be removed j Unlatch the right panel header panel latch located at the top of the windshield STO PO 23 020 08 6 k Carefully remove the right side panel from the hard top 2 Setthe Freedom Top panels on a wel PROTECTED WORK SURFACE Protect the Freedom Top panel edges amp top surface from damage NOTE THE PAINTED TOP SURFACE OF THE FREEDOM TOP CAN EASILY BE DAMAGED IF CARE IS NOT TAKEN TO PROTECT IT Fig 4 RIGHT FREEDOM PANEL COMPONENTS Black Foam Corner Patch D 972 E and Black Foam Patch D 1010 A 30mm x 95mm x 3mm thick Gray Foam Strip D 1012
43. kip Condition 4 Scuff trim foam damaged missing Repair 4 Replace trim clips Condition 5 Antenna grommet not sealed Repair 5 Re install grommet Figure 48 Labor Op Code 235001 20 Appendix Foam Kit 68026937AB CHERE ge of 269057 AG TSET 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 2 Labor Op Code Appendix Labor Op Code Jeep Wrangler Replacement Parts List LM 68027813AA Butyl esie api 2 7 10 14 04467708 Clear Sealer FoamKit 68026937AB ERR 55397454AE Windshield Header Seal 2 55395274 5AN Front Door Primary Seal 5 55395708 9AE B Pillar Mucket 15 55397095AG FreedomPanelSeal 55397046AF Hard Top Seal 4DR 14 55397058AF Hard Top Seal 2DR 14 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 Big Bb 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 doo
44. l in Gaps between Metal Wrinkles Holes and Notches in this area withibutyfunti smooth 3mmoe3 mr butyl pad as DI ni E Note Vehicles built after 6 1 2008 2 7 MDH have this area filled in with TA seam sealer from assembly plant completely covered by the header seal mucket in this area Be careful DO NOT allow squeeze out outside of installed mucket EN IF lolori d 10 14 2008 Right Side A pillar 8 Note Green dots Show the area 4 mm diameter bead 68027813AA where the header weather Strip Replacement Butyl Position See Adhesive Tape is to be located page 9 for Butyl Dimensions Locate each end of the E header weather strip n using this flange on Peach side In Right Side A pillar Locate and install NEW Weather Strip Pt Strip 55397454AB Remove Release tape and Pressurize Weather Strip 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 Weather Strip tape is adhered completely from side to side THIS STEP IS CRITICAL Gently pull weather strip rearward at mold line shown on page 9 and insert a 3 mm x 3 mm square piece of butyl 10 14 2008 10 10 14 2008 Right Side A pillar Header Seal Installed JK B Pillar Water Leak Repair Please note This package addresses water leaks that come from inside the
45. le amp foam already installed The steps on the next page show how to add the drain hole amp foam dam If B Pillar weather strip needs to be replaced order the following part numbers 09395 08AC RT Side 09395 09AC LT Side 9 4 2008 10 Note Single hole paper punch used to add Drain Hole a B Right B Pillar ALL VIEWS Foam Tape must be adhered to the front portion of the drain cup as shown to act as a dam Left B Pillar TOP VIEW 9 4 2008 12 JK Half Doors Water Leak Repair n Measuring of Door Posts For Proper Preload LA E E x 3 e SL e n hu 9 nre r Lo Li Lay Door on Flat Clean Surface Measure Posts Use Heat Gun to Heat up Posts as shown on page 3 Slide Pipe over Posts and Bend to Correct Dimension as shown on page 3 set this dimension as shown to the upper edge of each peg to the dimensions shown on page 3 9 4 2008 2 Heat Post Caution too much heat will melt Once heated Slide Pipever Post and Bend Post to Door Maintain 12 inches for 2 Min Max Correct Dimension Front Door Post Dimensions R amp L Front Post 46 0mm Hear Post 3 0mm Rear Door Post Dimensions R amp L Front Post 30 0mm Rear Post 40 0mm 9 4 2008 Note Dimensions are from flat surface to the top of post 3 Add 4 mm diameter bead 68027813AA Butyl Between Door Seal and door as shown on Page 5 Front Door Upper A Pillar C
46. leak category as listed below and provides all the necessary information and latest methods to make effective repairs The Labor Operations listed in the Service Bulletin can be used based on repair methods used in the manual The JK Water Leak Repair Manual has a diagnosis road map that includes the following customer concerns i Water is on center of Instrument Panel Shifter ii Water is on door trim panel or Instrument Panel at A pillar iii Water at rear hard top panel B pillar iv Water is on the front carpet SERVICE Stick with the Specialists 23 005 09 REV A 2 POLICY Reimbursable within the provisions of the warranty TIME ALLOWANCE 23 51 35 95 Diagnosis Top System for Water 0 4Hrs Leaks B 23 51 35 97 Inspect and Replace Windshield 0 9Hrs Header Seal B 23 51 10 90 Measure and Adjust Door Fit 0 7Hrs and Replace Primary Door Seal One Door Only B 23 51 41 91 Inspect A Pillar Mucket Seal O 4Hrs One Side Only B 23 51 41 92 Heseal Freedom Tops Both 0 5Hrs Freedom Panels B 23 42 63 90 Latch Freedom Panels Both 0 5Hrs Hight amp Left Freedom Panels B 23 51 35 98 Replace Hard Top Seal B 23 51 41 93 Replace B Pillar Mucket Seal 0 4Hrs One Side Only B 23 50 35 90 Repair Rear Wheel Flare Holes 0 7Hrs Both Sides Right and Left Sides B 23 50 40 90 Heseal Cowl Side Panel One 0 5Hrs oide Only B FAILURE CODE
47. mbers 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 Where to place butyl yum i Fi
48. nel Notch Note No gap between installed Weather Strip and outer edge of freedom panels Note Remove Release tape and Press Weather Strip Firmly 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 10 14 2008 19 If Vehicle MDH is Before 12 17 07 Replace this Latch on Right amp Left Freedom Tops with 68004562AB Freedom Panel Latch and Base Assembly Right and Left 10 14 2008 20 Flip Right Freedom Panel over to complete Weather otrip installation 10 14 2008 Remove Release Tape Locate W Strip cross car against in the freedom panel and Pressurize to Freedom Panel starting at the ends and working toward the center Cross Car Direction 22 10 14 2008 A Small Roller or firm finger pressure should be used to insure the Weather Strip tape is adhered from front to rear THIS STEP IS CRITICAL 10 14 2008 Top View Front page 25 Flame Tips Hear page 26 Note Make sure vertical rubber lip does not roll or get tucked under freedom panel Correct condition shown is Required at the Front AND Rear 10 14 2008 24 Apply 3M 4298 adhesive promoter on the under side of the flame tip and allow to dry Align Gray 30 X 75 mm Foam from kit along trim lines of Flame Tip Front Flame Tip under side 10 14 2008 25 Apply 3M 4298 adhesive promoter on the under side of the flame tip and allow t
49. nt of Vehicle F S Right Side Nis View L LE Page 3 of 5 Figure 3 Windshield Header Seal Molded Detail Upper A Pillar shown without tops Reference Locations A1 amp A2 p Dark Gray Foam at End of Header Seal Left Side of Windshield Frame shown 2 Windshield Header Seal 3 Windshield Frame Upper A Pillar Left Side Figure 4 Rear of left Freedom Panel shown Figure 5 Front of left Freedom Panel Figure 6 Rear of right Freedom Panel shown Reference locations B1 amp B2 shown Reference locations A1 amp A2 Reference location D 1 Blue highlighted foam 1 Orange highlighted foam 1 Dark green highlighted foam 2 2 way freedom panel locator 2 Red highlighted foam 3 Red highlighted foam Page 4 of 5 1 Figure 7 Front of left Freedom Panel showing one additional foam required only on vehicles built prior to 3 01 07 Reference locations A1 amp A2 1 Turquoise highlighted foam 1 Figure 8 Front of right freedom panel showing one additional foam required on vehicles built prior to 3 27 07 unless a new seal was installed as shown by photos on side Reference location C 1 Purple highlighted foam Page 5 of 5 07 Wrangler Water Leak Repair Refit door if header gap to top is greater than 7mm or door overflush to A or B pillar greater Out of spec door fit than 1mm Water drips on A pillar Trim or F
50. o dry Align Black 30 X 75mm Foam from kit along trim lines of Flame Tip ET 4 E 3 Ga m F 285 8423 Was A B i 19 Wi to Rear Flame Tip under side 10 14 2008 26 Trim away excess Black Foam Rear Flame Tip Top View 10 14 2008 27 Left Freedom Panel Place Left Freedom Panel Upside down on a covered work surface to prevent paint Scratching 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 Rear Inboard Corner Butyl amp Foam installation 10 14 2008 28 Add 4mm diameter Butyl Pt 68027813AA to Rear Inboard Corner groove Left Freedom Panel Note Push Butyl Firmly into groove between panels until Flush 100mm 10 14 2008 29 Add 30 X 75 mm Black Foam from Kit to cover butyl 10 14 2008 30 Add 30 X 75 mm Black Foam from Kit to cover butyl Note Make sure Foam covers Butyl IhuaG Cx Outboard 10 14 2008 31 Note REMINDER Refer to Page 20 If Vehicle MDH is Before 12 17 07 Replace Latch on Right amp Left Freedom Top with 68004562AB Left Freedom Panel complete 10 14 2008 32 JK A Pillar Header Weather Strip Water Leak Repair Please note This package addresses water leaks that come from inside the vehicle when the door is
51. o the inboard side grove Apply butyl adhesive for 100 mm into the rear groove The new butyl adhesive must fill the inboard and rear grooves but it must not overfill the groove it must be even with the surface Fig 25 ADD BLACK FOAM PATCH OVER BUTYL 1 Rear Inboard Corner Left Freedom Top Panel 2 New Butyl Adhesive Placed In Groove and Flush With Top Of Groove 3 Black Foam Patch 30 mm x 75 mm Install So It Is Flush With Edges Of Panel Press In Place 43 Each foam patch must cover the butyl adhesive Add one 30 mm x 75 mm BLACK foam patch over the new butyl along the inboard edge of the rear inboard corner The butyl must not stick out from under the foam Fig 25 1 23 020 08 Fig 26 FOAM PATCHES COVERING BUTYL 1 Rear Inboard Corner Left Freedom Top Panel 2 Black Foam Patch 30 mm x 75 mm Install So It Is Flush With Edges Of Panel Press In Place 3 Black Foam Patch 30 mm x 75 mm Install So It Is Flush With Edges Of Panel Press In Place 44 Each foam patch must cover the butyl adhesive Add one 30 mm x 75 mm BLACK foam patch over the new butyl along the rear edge of the rear inboard corner The butyl must not stick out from under the foam Fig 26 Replace Left Panel Header Latch 45 If vehicle was built prior to December 17 2007 MDH 1217XX then replace the left panel header latch Fig 1 Outboard Corners Both Freedom Top Panel Fig 27 CHECK OUTSIDE CORNERS FOR FOAM Outboard Co
52. or 55397046AF 4 DR Place seal tight against roof without gaps as shown on page 5 Hemove Helease tape amp Pressurize Weather Strip Firmly in contact with Roof to smooth out adhesive tape Make sure adhesive tape is FIRMLY PRESSURIZED against the roof panel while maintaining a zero gap condition from side to side small Roller or firm finger pressure should be used to insure the Weather Strip tape is adhered completely side to side THIS STEP IS CRITICAL 9 4 2008 7 B Pillar Weather Strip Remove B Pillar Mucket Weather Strip from body and clean up remove all traces of old Tape and Butyl from painted surfaces before reinstallation of butyl bead and new weather strip Clean Seal Surface with 3M General Purpose Adhesive Cleaner or Kent Products Acrysol if available and allow to dry completely PAGE S 9 amp 11 Show the RIGHT SIDE B PILLAR amp PAGE 12 SHOWS THE LEFT SIDE THESE REWORKS MUSI BE DONE ON BOTH SIDES OF IHE TRUCK Mucket Removal Clean Up Butyl amp Mucket install and Mucket drain hole and Dam rework 9 4 2008 8 Add a 4 mm diameter bead of Butyl 68027813AA as shown to fill in sheet metal gaps 5 or LI a T if E LU A u SS i pe unu a ele n rmm iit i T Top of Right B Pillar With Mucket Seal remo n n a pore aer ved 9 4 2008 B Pillar Weather Strip Vehicles built After July 1 2008 will have the drain ho
53. orner 9 4 2008 4 Add 4mm Diameter Butyl bead 6 inches forward and 6 inches rearward as shown In Close up view of area circled on page 4 Front of Door 9 4 2008 5 Make Sure Seals Are Installed Correctly Seal is not seated in channel Correct 9 4 2008 6 MUCKET 68003655AB KIT DOOR RAIL SEAL 4DR JK A PILLAR FOAM A PILLAR FRONT FOAM C PILLAR FOAM 9 4 2008 MUCKET 68003645AB KIT DOOR RAIL SEAL I A PILLAR FOAM A PILLAR FRONT FOAM B PILLAR FOAM 9 4 2008 JK Soft Top Water Leak Repair Tips a Header Seal Cup Folded under 10 14 2008 Correct 2 Quarter Window Installation CES as Incorrect Retainer Not Rolled into Door Hail Correct 10 14 2008 Half Door Side Curtain or Rear Window Zipper Leaks Can Be repaired by using Beeswax or Snow Seal as a sealant E E un 10 14 2008 Water eeping Through Zipper Tape or Zipper Teeth MUCKET 68003655AB KIT DOOR RAIL SEAL 4DR JK A PILLAR FOAM A PILLAR FRONT FOAM C PILLAR FOAM 10 14 2008 MUCKET 68003645AB KIT DOOR RAIL SEAL I A PILLAR FOAM A PILLAR FRONT FOAM B PILLAR FOAM 10 14 2008 JK Water Leak Foam Repair Kit Supplemental Information P N 68026937AA 23 041 07 Soft Top Water Leak at Upper A Pillar Door Seal to Door Rail Interface Foam to be installed Foam to be installed 23 001 07 Modular Hard Top Freedom P
54. r is closed This package does not address water 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 7mm OD x 71mm 2 pieces 13mm OD x 8mm ID x 160mm 1 piece Y E i es i Wi Wu a a n b Y Ji LA 4 9 mm x 100 mm x 6 35 mm thick 2 pieces I 30 mm x 75mm x 2 mm thick 1 piece Gray Foam thick 3 pieces Black Foam 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 10 14 2008 s 6 us ES Hight 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 amp Tape from Right Freedom Panel 10 14 2008 9 Note Old Butyl Removed from Right Freedom Panel Seal Surface White Strip NT C 20 NES fy Le x SPA 8 F 2 CT 4 eo Ad i d 4 FA FN a ES E 4 X EN 4 p N d E m Pi A TN PE Clean Seal Surface with 3M General Purpose Adhesive Cleaner or Kent Products Acrysol if available and allow to dry comple
55. r may be the result of a Freedom Top seal leaking and running forward The following step verifies leak origination point 2 If leak occurs at the front of the top near the A Pillar remove the sun visors upper and lower trim covers to gain visual access to the header seal Water leaks originating from the header seal will generally run towards the outside ends of the header toward the A Pillar and drip in at the corner s 3 Ifa water leak is originating at the header seal then perform the Repair Procedure in this Service Bulletin and refer to Dealer CONNECT gt eFiles gt Service gt Star Center gt Misc Documents JK A Pillar Water Leaks for additional information PARTS REQUIRED 55397454AD Seal Windshield Header Freedom Top AR 82300508AB n Corrosion Inhibitor 5 oz Brush Top Tube or equivalent cL 08984 3M General Purpose Adhesive Cleaner or equivalent 06396 3M Adhesive Promoter 2 5 cc Packet or Equivalent Box of 25 1 box will service 25 vehicles udi 68027813AA Butyl Tape 4 mm dia x 152 mm 6 inch length strip REPAIR PROCEDURE NOTE Do not use RTV as a sealer Over time RTV will not remain attached to the hard top material 23 025 08 4 1 Remove both Freedom Top Panels from the hard top Perform the following steps in order a Fold both sun visors down and out of the way b Turn both left panel center L shaped locks 2 so that they disengage from the right side panel c
56. rner Right or Left Freedom Top Panel Rear Outboard Corner Shown Black Foam Corner Patch Used At Front and Rear Outboard Corners D 972 E for RIGHT Panel and D 973 E for LEFT Panel Black Foam Patch D 1009 A 20mm x 95mm x 5mm thick Used At Rear Outboard Corner Lt And Rt Panels to Hard Top Seal N solator Black Plastic 46 With the LEFT PANEL locate the rear outboard corner of the panel 47 Note the location of the old foam patches Remove the old foam patches from the rear outboard corner of the left panel 48 Thoroughly clean all old adhesive residue from the rear outboard corner surface using a high quality adhesive remover 49 Carefully install a new Black Foam Corner Patch to the rear outboard corner surface Ensure that no wrinkles are in the foam patch 50 Carefully install the Black Foam Patch 20mm x 95mm x 5mm to the rear outboard corner surface Ensure that no wrinkles are in the foam patch 51 Move to the Front Outboard of the left panel 52 Note the location of the old black foam corner patch Remove the old foam patch 53 Thoroughly clean all old adhesive residue from the front outboard corner surface using a high quality adhesive remover 54 Carefully install a new Black Foam Corner Patch to the front outboard corner surface Ensure that no wrinkles are in the foam patch 55 Verify that the black plastic isolator is in place and not damaged Replace the isolator if damaged or missing 5
57. ront Door end of IP Adjust bracket flange behind end Header Seal ends offset to top panel detail in or out to flush up detail to or rail top Sealer skip miss along back of Door Add repair sealer to close off Seal mounting Channel sealer skip Door Primary seal not fully installed to Reinstall loose sections into channel on door channel Holled or distorted cup o Heseat top to seal detail windshield header seal or B A straighten seal cup for smooth seals transition to top Distorted folded Windshield Cowl Heseat seal detail to windshield Seal end detail frame Missing or off location Foam transition patch near Windshield Cowl Seal Relocate or replace foam seal Locate leak path during test Verify seal condition is not damaged Door Primary seal not sealing along Adjust door fit or add insert stuffer body surfaces to seal if required Doors 1 Water leaks down B pillar Trim or along inner surface of door at B pillar from door header Water leaks down Rear Door opening at trim fabric trim panel or door inner Front Door Upper B Pillar 2 or 4 door 4 Door Rear Door Upper B Pillar 0 Wrangler Water Leak Repair Out of spec door fit Front cup of B pillar mucket folded distorted Hardtop Seal adhesive tape not wetout across end details amp center detail Out of spec door fit Rear cup of B pillar mucket folded distorted Inconsistent Hardtop foam tape butyl application a
58. t ends on 4 door top If soft top poor transition on B pillar molded detail to rail may be present Refit door if header gap to top is greater than 7mm or door overflush to B or C pillar greater than 1mm Loosen or remove top reseat amp straighten mucket lip for smooth transition Inspect Hardtop seal center detail for leak paths and source Refer to Hard top Outboard End Leak file for further information Refit door if header gap to top is greater than 7mm or door overflush to A or B pillar greater than 1mm Loosen or remove top reseat amp straighten mucket lip for smooth transition Refer to Hard top Outboard End Leak file for further information Replace or relocate foam on rail to extend between 1mm 3mm past edge of seal lip 07 Wrangler Water Leak Repair JEEP WRANGLER a w i oa r Door header gap to top not to S exceed 7mm and Door to body flush along pillars to be no greater than 1mm Doors 07 Wrangler Water Leak Repair Poor offset from windshield header end seal to top can cause leak between body amp door Adjust flange behind detail in or out to flush up detail Doors oors Rolled or distorted windshield header end seals can cause leaks by making a poor transition for the primary seal to seal against 07 Wrangler Water Leak Repair Holled or distorted B pillar mucket seals can cause leaks by making a poor transition for
59. tely Rough up Seal ourface with Medium Scotch Bright pad Wipe Seal Surface with Alcohol and allow to dry completely 10 14 2008 10 Note Old Butyl Removed from Right Freedom Panel Front amp Hear Notches 10 14 2008 11 Place Right Freedom Panel Upside down on a covered work surface to prevent paint ocratching Freedom Panel Notch Butyl installation 10 14 2008 12 Page 15 Hear notch Page 14 Front notch 10 14 2008 13 Apply New 4 mm diameter Butyl Pt 6802 813AA to Right Freedom Panel Front Notch Note Follow Groove between panels and Push Butyl firmly in place Inboard A A Butyl inside Grooves eam 15 mm 10 14 2008 Apply New 4 mm diameter Butyl Pt 6802 813AA to Right Freedom Panel Rear Notch Note Follow Groove between panels and Push Butyl firmly in place a bons Butyl inside Grooves A a 10 14 2008 15 Page 1 Hear 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 Smooth out Butyl after W Strip installation PEL uS SESS b E r 10 14 2008 17 Align Front edge of NEW Weather Strip Pt 55397095AG to Right Freedom Pa
60. 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 68026937 AB Figure 11 mem i STEP 2 Foam installation 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 Remove seal on 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 Notch Figure 18 e Note Follow groove between panels and push
61. up at the center This could cause a water leak path otarting at one end remove a few inches of the release tape and press the center seal into place Move to the other end of the center seal and remove a few inches of the release tape and press the center seal into place Alternate back and forth from end to end working towards the center until the release tape is completely removed and the center seal is in place Fig 14 FIRMLY PRESS SEAL INTO PLACE 1 Middle Section Center Seal 2 Rear Molded Detail Section Center Seal 3 Start At Each End Of Center Seal And Work Towards The Center Of the Seal Firmly Press The Seal Into Place 23 020 08 12 Fig 15 CENTER SEAL HAND ROLLER 1 Right Freedom Top Panel 2 Hand Roller Use Roller Adhere Butyl To The Panel Important Step 3 Center Seal 26 21 28 29 To make sure the front and rear molded ends of the center seal do not move out of place start at the ends of the seal and carefully working toward the center of the seal install the middle section of the center seal to the panel Once the middle section is attached to the panel go back over the entire length of the middle section of the seal with your hand to ensure that the seal is firmly attached to the Freedom Top panel IMPORTANT Complete the installation of the center seal by applying pressure with a roller to the new center seal Make certain that the roller will not damage the new center seal IMPO
62. vehicle when the door is closed This package does not address water that drips into the Vehicle when the door is open This is a normal condition 9 4 2008 2 1 Windshield header seal 2 Windshield to cowl seal 3 Front door weatherseal 4 B pillar mucket 5 Hard top seal Outside View 6 Center freedom panel seal 9 4 2008 3 Note Seal Shown with sealer skips allows water behind seal This requires the need for additional Butyl to be placed to fill in these voids L e Hard Top Seal at Center W Strip Repair Try this step Prior to Replacement 9 4 2008 4 Hard Top Seal at Center __ Note Seal Shown gapping to roof 9 4 2008 allows water behind seal This requires the seal to be replaced _ Pr i 3 he entire seal length sidet TE Side top If tape is not firn replace the seal Hard Top Weather Strip Remove Hard Top Weather Strip from Hard Top and clean up remove all traces of old Tape and Butyl from painted surfaces before reinstallation of new weather strip Clean Seal Surface with 3M General Purpose Adhesive Cleaner or Kent Products Acrysol if available and allow to dry completely Weather Strip Removal amp Butyl Clean Up 9 4 2008 6 Hard Top Weather Strip Alcohol wipe the clean painted surfaces And Allow Alcohol to dry completely before insallation of new weather strip Locate amp install NEW Weather Strip Pt 55397058AI 2 DR
63. with Dual Tops Soft and Freedom Top should have this bulletin performed with the Freedom Top installed The replacement header seal may initially cause a soft top wind noise 23 025 08 6 Replace Windshield Header Seal NOTE If seal requires replacement then the old seal adhesive must be completely removed before a new seal is installed Use a GOOD quality adhesive remover as recommended in Parts Required section of this Service Bulletin Drill out rivets at each end of the header seal with 1 8 drill bit Hemove header weatherstrip from body sheet metal Remove all traces of old tape and butyl from painted sheet metal on header Use p n 08984 3M General Purpose Adhesive Cleaner or equivalent to remove 7 Treat surface with 06396 3M Adhesive Promoter pad or equivalent Allow to completely dry 8 Install butyl to fill gaps in sheet metal or wrinkles holes and notches in thumb sealer in the area describe in Fig 3 9 Carefully smooth butyl to form a smooth transition to the header sheet metal 10 Treat rivet hole bare metal with p n 82300508 Mopar Corrosion Inhibitor OR 8200d5a7 Fig 3 BUTYL INSTALLATION DIMENSIONS 1 Item_1 2 ltem_2 11 Before removing tape backing lay the new header weatherstrip p n 55397454AD in place on header to align 12 Remove tape backing and press weatherstrip firmly to header sheet metal and smooth out adhesive tape NOTE A small roller or firm finger pressure should

Jeep Wrangler Diagnosis & Repair Manual Water Leaks

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Jeep Wrangler Diagnosis &amp; Repair Manual Water Leaks

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Jeep Wrangler Diagnosis & Repair Manual Water Leaks