Jeep Wrangler TJ. Manual — part 545
(5) Position the hinge on the vehicle body. Align
the wax pencil marks installation alignment refer-
ence marks. Install the screws.
(6) Install the door. (Refer to 23 - BODY/FULL
DOOR/DOOR - INSTALLATION)
(7) Inspect the windshield alignment after hinge
installation.
(8) Inspect the door alignment and adjust, if nec-
essary. (Refer to 23 - BODY/FULL DOOR/DOOR -
ADJUSTMENTS)
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the torx screw attaching the inside
handle to the door.
(2) Carefully pull the handle from the door.
(3) Disconnect the latch rods from the handle (Fig.
10).
INSTALLATION
(1) Connect the latch rods to the handle.
(2) Position handle and seal in door.
(3) Install the torx screw attaching the inside han-
dle the to door.
LATCH
REMOVAL
(1) Remove trim panel. (Refer to 23 - BODY/FULL
DOOR/TRIM PANEL - REMOVAL)
(2) Roll window to full upward position.
(3) Disconnect the lock cylinder to latch rod. (Fig.
11)
(4) Disconnect the lock knob to latch rod.
(5) Disconnect the outside handle to latch release
rod.
(6) Remove the screws attaching the latch to the
door.
(7) Lower the latch in the door and disconnect the
inside handle to latch rod.
(8) Remove the latch from the door.
INSTALLATION
(1) Position the latch in the door.
(2) Connect the inside handle to latch rod.
(3) Install the screws attaching the latch to the
door.
(4) Position the door weatherstrip in place, apply
adhesive as necessary.
(5) Connect the outside handle to latch rod.
(6) Connect the lock knob to latch rod.
(7) Connect the lock cylinder to latch rod.
(8) Install trim panel. (Refer to 23 - BODY/FULL
DOOR/TRIM PANEL - INSTALLATION)
Fig. 10 INSIDE HANDLE ACTUATOR
1 - LOCK KNOB TO LATCH ROD
2 - U-NUT
3 - HALF DOOR TRIM PANEL
4 - INSIDE RELEASE HANDLE TO LATCH ROD
Fig. 11 DOOR LATCH ASSEMBLY
1 - RELEASE ROD
2 - SCREWS (3)
3 - LATCH ASSEMBLY
4 - LOCK ROD
23 - 22
FULL DOOR
TJ
HINGE (Continued)
LATCH STRIKER
REMOVAL
(1) Remove the screws attaching the striker to the
body.
(2) Separate the striker and the spacer from the
body (Fig. 12).
INSTALLATION
(1) Position the striker and the spacer on the body.
(2) Install the screws attaching the striker and
spacer to the body.
LOCK CYLINDER
REMOVAL
(1) Remove trim panel. (Refer to 23 - BODY/FULL
DOOR/TRIM PANEL - REMOVAL)
(2) Peel back waterdam.
(3) Disconnect lock cylinder to latch rod.
(4) Remove lock cylinder retaining clip.
(5) Remove the lock cylinder from the door.
INSTALLATION
(1) Install the lock cylinder in the door.
(2) Install lock cylinder retaining clip.
(3) Connect lock cylinder to latch rod.
(4) Secure the waterdam to the door.
(5) Install trim panel. (Refer to 23 - BODY/FULL
DOOR/LOCK CYLINDER - INSTALLATION)
TRIM PANEL
REMOVAL
(1) Lower the window.
(2) Remove the clip attaching the window glass
regulator handle to the regulator. Remove the han-
dle.
(3) Remove the screws attaching trim panel to
door (Fig. 13).
(4) Using a special tool C-4829 or equivalent,
remove push-in fasteners attaching trim panel to
door.
(5) Lift the trim panel upward and separate the
trim panel from the door.
INSTALLATION
(1) Position the trim panel on the door.
(2) Press the push-in fasteners attaching trim
panel to door into place.
(3) Install the screws attaching trim panel to door.
(4) Position the clip on regulator handle and
install the handle on the regulator.
Fig. 12 LATCH STRIKER
1 - STRIKER
2 - SPACER
3 - BODY
Fig. 13 FULL
1 - FULL DOOR
2 - GRAB HANDLE BRACKET
3 - TRIM PANEL
4 - NUT
TJ
FULL DOOR
23 - 23
HALF DOOR
TABLE OF CONTENTS
page
page
DOOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 24
WINDOW
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 24
EXTERIOR HANDLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 25
HINGE
. . . . . . . . . . . . . . . . . . . . . . . . . 25
INSIDE HANDLE ACTUATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 25
LATCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 26
LATCH STRIKER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 26
LOCK CYLINDER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 26
TRIM PANEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 26
DOOR
REMOVAL
(1) Open the door.
(2) Disconnect the door restraint strap from the
pin (Fig. 1).
(3) Remove the nuts at the door hinge pivots and
lift the door from the body.
INSTALLATION
(1) Position the door in the hinge and install the
nuts.
(2) Connect the door restraint strap at the pin.
(3) Check for proper operation.
WINDOW
REMOVAL
(1) Open the door.
(2) Grasp the window at both front and rear edges
and firmly lift upward (Fig. 2).
INSTALLATION
(1) Starting at the most forward alignment pin,
position the window alignment pins into the restraint
sleeves and push downward until seated.
Fig. 1 RESTRAINT STRAP
1 - BODY
2 - FOOTMAN LOOP
3 - STRAP
4 - RESTRAINT PIN
Fig. 2 HALF WINDOW
23 - 24
HALF DOOR
TJ
EXTERIOR HANDLE
REMOVAL
(1) Remove trim panel. (Refer to 23 - BODY/HALF
DOOR/TRIM PANEL - REMOVAL)
(2) Disconnect the outside handle to latch rod.
(3) Remove screws attaching the outside handle to
the door.
(4) Separate the outside handle and seal from the
door.
INSTALLATION
(1) Position the outside handle and seal in the
door.
(2) Install screws attaching the outside handle to
the door.
(3) Connect the outside handle to latch rod.
(4) Install trim panel. (Refer to 23 - BODY/HALF
DOOR/TRIM PANEL - INSTALLATION)
HINGE
DESCRIPTION
The service procedures for the half door hinge are
the same as the full door hinge. (Refer to 23 - BODY/
FULL DOOR/HINGE - REMOVAL) and (Refer to 23 -
BODY/FULL DOOR/HINGE - INSTALLATION).
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the torx screw attaching the inside
handle to the door.
(2) Carefully pull handle from door.
(3) Disconnect the latch rods from the handle (Fig.
3).
INSTALLATION
(1) Connect the latch rods to the handle.
(2) Position handle and seal in door.
(3) Install the torx screw attaching the inside han-
dle the to door.
LATCH
REMOVAL
(1) Remove trim panel. (Refer to 23 - BODY/HALF
DOOR/TRIM PANEL - REMOVAL)
(2) Disconnect the lock cylinder to latch rod (Fig.
4).
(3) Disconnect the lock knob to latch rod.
(4) Disconnect the outside handle to latch rod.
(5) Using a trim stick or equivalent, pry back the
door weatherstrip at the latch to access the screw
attaching the latch to the door.
(6) Remove the screws attaching the latch to the
door (Fig. 5).
(7) Lower the latch in the door and disconnect the
inside handle to latch rod.
(8) Remove the latch from the door.
Fig. 3 INSIDE HANDLE ACTUATOR
1 - LOCK KNOB TO LATCH ROD
2 - U-NUT
3 - HALF DOOR TRIM PANEL
4 - INSIDE RELEASE HANDLE TO LATCH ROD
Fig. 4 HALF DOOR LATCH RODS
1 - LOCK CYLINDER
2 - HALF DOOR
3 - HALF DOOR
4 - LATCH
5 - LOCK CYLINDER TO LATCH ROD
6 - LOCK CYLINDER
7 - RETAINER
8 - OUTSIDE HANDLE
9 - INSIDE HANDLE TO LATCH ROD
10 - INSIDE LOCK TO LATCH ROD
TJ
HALF DOOR
23 - 25
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