Repair Procedure

This repair procedure involves replacing the door division bar assembly.





The door assembly is shown in Figure 1. Views A-G are shown in the repair procedure as necessary.



1. Remove the trim panel.

2. Remove the sound deadener and watershield.





3. Carefully remove the door division bar end cap screws or rivets (Figure 2 View A) and remove the door end cap by separating it from the adhesive. Inspect the end cap for damage and order a new one if required. The end cap will be installed during assembly.



4. Loosen the tensioner bolt and slide the tensioner downward.

5. Run the glass down so that two inches of the regulator gear shows in the large access hole.





6. Remove the rivets holding the regulator to the door inner panel using a 6.35 mm (1/4 in.) drill bit (Figure 3, View B).


CAUTION:
AVOID RIVETING ON OR NEAR THE GLASS OR DAMAGE TO THE GLASS MAY RESULT.






7. Loosen upper tensioner bolt (Figure 4, View C)



8. Remove the door glass by lifting and sliding the glass out of the division channel while disengaging and sliding it off the regulator roller.

9. Inspect the lift channel for damage. If it is damaged continue with step 11, if there is no damage, go to step 15.





10. Remove the lift channel rivet by drilling them out with a 6.35 mm (1/4 in.) drill bit (Figure 5, View D).



11. Turn the glass over and use a punch to clear the debris from the rivet area.

12. After loosening the rivets, remove them by prying them off.

13. Remove the plastic gaskets from the glass and discard.

14. Remove the lift channel from the glass and discard.

15. Remove the pins and retainers from the holes in the glass that are covered by the glass guide.

16. Remove the glass guide from the glass and discard. Mark the position of the mylar before removing.

NOTE:
MARK THE EDGE OF THE DOOR DIVISION BAR ON THE DOOR A-PILLAR TO INDICATE THE FORE/AFT POSITION FOR REFERENCE LATER.





17. Remove the division bar bolts from the middle and bottom of the division bar (Figure 6, View E).






18. Remove the division bar attaching rivets from the holes in the bracket by drilling them out with a 1/8 in. (3.17 mm) drill bit (Figure 7, View F).



19. Remove the door division bar and stationary glass as one assembly through the top of the door. Remove the L-bracket (with U-nut) from the bottom of the division bar and install the new division bar with new fasteners as needed.

20. Remove the door stationary glass with the seal from the division bar channel and discard the bar.

21. Remove the old U-nut and attach it to the bracket at the middle of the new division bar.





22. Inspect the belt line bracket attachment to the door inner sheet metal. (See Figure 4). If it is loose, drill out the rivets and install new ones. Then attach two additional rivets penetrating both the bracket and inner door panel sheet metal. Apply paint to the bare metal edges.

23. Press the door stationary glass and seal into the new division bar channel.

24. Install the door stationary glass with the bar through the top of the door, twisting inward to find the correct position. Use the reference marks made earlier in step 16.

NOTE:
THE DOOR DIVISION BAR TAB MUST FIT BETWEEN THE SEAL AND THE A-PILLAR.

25. Install the division bar retaining bolts at the middle and bottom locations loosely.





26. Drill one 3.17 mm (1/8 in.) hole in the division bar tab by aligning it in the door frame and install one 3.17 mm (1/8 in.) x 4.76 mm (3/16 in.) stainless steel rivet to the tab pillar hole in the bracket. Two more rivets will be installed later. Apply paint to the bare metal edges (Figure 8).

CAUTION:
AVOID DRILLING ON OR NEAR THE GLASS OR DAMAGE TO THE GLASS MAY RESULT.



27. Tighten the division bar "L" bracket bolts on the bottom and middle attaching points to 100 in.lbs. (11.2 N-m) torque. (This may require cycling the glass to adjust the position of the slot in the bracket.)





28. Position the glass guide (mylar) on the moveable glass aligning the holes (Figure 9, View G).



29. Insert the pins through the glass guide holes and the holes in the glass by pressing the two plastic retainers from opposite sides. Attach one retainer to the pin first and then press the pin over and through the glass guide, connecting the other retainer. Repeat this procedure for each hole.

30. Install the lift channel on the glass with the gaskets (if removed earlier).

31. Install the lift channel rivets.

CAUTION:
AVOID RIVETING ON OR NEAR THE GLASS OR DAMAGE TO THE GLASS MAY RESULT.

32. Roll the regulator down until two inches of rack shows in the large access hole.

33. Install the door glass by sliding the glass into the division channel and engaging the door glass by sliding it onto the regulator roller.

NOTE:
SPRAY BOTH THE DIVISION BAR AND CHANNEL AND REAR CHANNEL WITH SILICONE LUBRICANT TO AID IN ASSEMBLY AND OPERATION.

34. Install the four regulator-to-door rivets by holding the regulator to the door inner panel. Install the lower rivet first to position the regulator. These rivets are not included in the parts package.

35. Tighten the regulator bolt to 11.3 N-m (100 in.lbs.) torque.





36. Drill two additional 1/8 in. (3.17 mm) holes in the division bar tab, (one on the end of the tab) by aligning the tab in the door frame. Install two 1/8 in. x 3/16 in. (3.17 mm x 4.76 mm) stainless steel rivets in the tab pillar holes in the bracket, The tab pillar bracket tucks under the door A-pillar door frame, not over the top (Figure 8). Apply paint to the bare metal edges.

CAUTION:
AVOID RIVETING ON OR NEAR THE GLASS OR DAMAGE TO THE GLASS MAY RESULT.

37. Position the door end cap. Inspect the gap between the black outer channel on the division bar and end cap.

a. If there is no gap, go to step 39.

b. If there is a gap, go to step 38.

38. Remove the door end cap to adjust the division bar trim.

Two people are required:

a. One person grasps both sides of the division bar trim and slides it up while the other gently taps on top of the division bar with a rubber mallet.

b. When the black trim has been moved upward, the new position should eliminate the gap as seen in step 37.

39. Install the door end cap using black weatherstrip adhesive.

NOTE:
THE DOOR END CAP SEAL IS ATTACHED TO THE END OF THE DOOR END CAP. IF IT WAS REMOVED IT MUST BE ATTACHED AGAIN USING LOCTITE SUPER BONDER NO. 495.

40. Apply silicone sealer along the entire inner front edge of the door end cap molding.

NOTE:
WITH THE DOOR IN THE CLOSED POSITION AND THE TOP STACK LATCHED, CHECK TO ENSURE THAT THE END CAP MOLDING DOES NOT INTERFERE WITH THE HEADER WEATHERSTRIP. (ADJUST FORE AND AFT AS NECESSARY TO ELIMINATE INTERFERENCE).



41. Install the door end cap retaining rivets (black).

42. Install the watershield and sound deadener.

43. Install the trim panel.


POLICY:
Reimbursable within the provisions of the warranty.


TIME ALLOWANCE:
Labor Operation No. 23-31-61-90/91 . . . . . 1.5 Hrs.


FAILURE CODE:
P8 - New Pad