Front Door: Service and Repair

BALLISTIC DOOR PANEL

Special Tool(s):

Special Tool(s)

Ballistic Door Panel Insert:

Removal
1. Remove the front door glass top run.
2. Remove the front door window regulator and motor.
3. Remove the front door latch.







4. Remove the bolt on the forward ballistic door panel.







5. Remove the bolt on the rearward ballistic door panel.







6. Remove the center bolt of the ballistic door panel.







7. Slide the forward ballistic door panel as far to the front as possible and remove the rearward panel.
8. Remove the forward ballistic door panel.

Installation

1. NOTE: If installing ballistic door panels in a new door or on a vehicle which has received a new front door outer panel, make sure to first install the protective film. If only reinstalling the ballistic door panels, skip to step 4.

Install protective film to front door outer panel belt line, position to the bottom of the belt line flange.

2. NOTE: If installing ballistic door panels in a new door, make sure to first install the foam tape to the intrusion beam to prevent panel rattle. If only reinstalling the ballistic door panels, skip to step 4.

Apply a double-layer of the foam tape to the intrusion beam.

3. Install the j-clips.

4. Insert the forward ballistic door panel through the window opening and hook the top bracket over the outer belt line sheet metal.
- Position as far forward as possible.

5. Insert rearward ballistic door panel through the window opening and hook the top bracket over the outer belt line sheet metal.
- Slide the forward panel back until mated with the rearward panel.

6. Align the panels so the ceramic plate bottoms out against the adjacent panel.







7. Install the bolt in the lower L-bracket.
- Tighten to 12 Nm (9 lb-ft).







8. Install the bolt in the rearward intrusion beam bracket j-clip but do not tighten.







9. Install the bolt in the forward intrusion beam bracket j-clip but do not tighten.
10. Visually inspect to ensure there is no gap between the panels. Adjust as necessary.
11. Tighten the rear bolt to 12 Nm (9 lb-ft).
12. Tighten the forward bolt to 12 Nm (9 lb-ft).
13. Install the front door latch.
14. Install the front door window regulator and motor.
15. Install the front door glass top run.