1995 JEEP YJ Service And Repair Manual

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Page 2041 of 2158

JEEP YJ 1995 Service And Repair Manual INSTALLATION
(1) Inspect the retainer clip and the gasket. As ap-
plicable, replace if distorted or damaged.
(2) Attach the lever to the lock cylinder with the
E-clip and position the lock cylinder in

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JEEP YJ 1995 Service And Repair Manual HARD TOP LIFTGATE GLASSÐYJ
REMOVAL
(1) Disconnect the rear defroster/dome lamp wire
harness connectors.
(2) Remove the wiper motor cover. Disconnect the
wiper motor wire harness connector and the was

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JEEP YJ 1995 Service And Repair Manual (8) Separate the liftgate glass from the hard top.
(9) Remove the weatherstrip seal (Fig. 2), if neces-
sary.
INSTALLATION
(1) Assemble the liftgate components, if necessary
(2) Position the liftgate

(8) Separate the liftgate glass from the hard top.
(9) Remove the weatherstrip seal (Fig. 2), if neces-
sary.
INSTALLATION
(1) Assemble the liftgate components, if necessary
(2) Position the liftgate glass in the hard top open-
ing and install the hinge bolts. Do not tighten the
bolts.
(3) Adjust the liftgate glass to fit the hard top
opening.
(4) Tighten the hinge bolts to 11 Nzm (95 in-lbs)
torque.
(5) Position the support rod cylinders on the ball
studs.
(6) Install the support rod cylinder retainer clips.
(7) Connect the wiper motor wire harness connec-
tor and the washer fluid hose. Install the wiper mo-
tor cover (Fig. 1).
(8) Install the wiper arm and blade.
(9) Connect the rear window defroster/dome lamp
wire harness connectors.
DISASSEMBLY
(1) Remove retaining screws and the lower, inner
trim molding from the latch panel (Fig. 3).
(2) Remove the retaining screws and the latch
panel, inner gasket, outer gasket, and the lower,
outer liftgate molding from the liftgate (Fig. 3).
(3) Refer to Group 8, Electrical for service informa-
tion involving the wiper motor and the defroster.
(4) If necessary, remove the latch strikers and the
ball stud brackets from the hard top inner panel (Fig.
3).
ASSEMBLY
(1) If removed, install the latch strikers and the
ball stud brackets on the hard top inner panel (Fig.
3).(2) Position the latch panel, and gaskets, and lift-
gate molding on liftgate and install screws (Fig. 3).
Tighten the screws to 7 Nzm (60 in-lbs) torque.
(3) Position the lower, inner trim molding on the
latch panel. Install screws (Fig. 3). Tighten the
screws to 2 Nzm (12 in-lbs) torque.
LIFTGATE GLASS WEATHERSTRIP SEAL
REPLACEMENTÐYJ
REMOVAL
(1) Remove the liftgate glass from the hard top. If
necessary, refer to the removal procedure.
(2) Remove the retaining screws from the liftgate-
to-tailgate weatherstrip seal (Fig. 4).
(3) Carefully separate the seal and retainers from
the bottom of the liftgate glass.
(4) Remove the hard top weatherstrip seal retain-
ing screws from body rear panels.
(5) Carefully separate the weatherstrip seal from
the rear panels and the hard top.
(6) Remove the residual adhesive from the seal
contact areas.
INSTALLATION
(1) Remove the tape cover and position the liftgate-
to-tailgate weatherstrip seal at the bottom of the lift-
gate glass (Fig. 4).
(2) Carefully insert the retainers into the holes
and press the seal against the bottom of the liftgate
glass.
(3) Install the liftgate-to-tailgate weatherstrip seal
screws Tighten the screws securely.
Fig. 3 Liftgate and Components
Fig. 4 Liftgate Glass Weatherstrip Seals
JEXTERIOR COMPONENTSÐYJ 23 - 125

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JEEP YJ 1995 Service And Repair Manual (4) Apply weatherstrip adhesive to the hard top
weatherstrip seal (Fig. 4).
(5) Carefully position the weatherstrip seal on the
rear panels and the hard top.
(6) Press the seal onto the hard top flang

Page 2045 of 2158

JEEP YJ 1995 Service And Repair Manual HARD TOP ROOF VENTÐYJ
REMOVAL/INSTALLATION
(1) Remove the roof vent retaining screw from the
spring nut (Fig. 1).
(2) Remove the roof vent from the hard top.
(3) Position the roof vent on the hard to

HARD TOP ROOF VENTÐYJ
REMOVAL/INSTALLATION
(1) Remove the roof vent retaining screw from the
spring nut (Fig. 1).
(2) Remove the roof vent from the hard top.
(3) Position the roof vent on the hard top and in-
stall the retaining screw.
HARD TOP REPAIRÐYJ
The hard top fiberglass material can be repaired.
The required repair materials include:
²Fiberglass mat or cloth.
²Fiberglass resin and hardener.
²structural adhesive (3M brand or an equivalent
product).
²Glazing putty.
²Aluminum foil.
²Plastic spreader.
HARD TOP HOLE REPAIR
(1) Use a grinder to remove the paint and outline
the damaged area. Use a grade 24 grit disc for paint
removal.
(2) Grind the outlined surface area again to a 50
grit disc to prevent coarse scratches from appearing
in the final finish.
(3) If cracks extend from the hole, it will be neces-
sary to stop-drill the crack(s) with a 3-mm (1/8-in) di-
ameter drill bit.
(4) Position a fiberglass mat or cloth on the repair
surface area. Cut the mat to allow a 2.5-cm (1-in)
overlap of the repair surface area.
(5) Clean the repair surface area.
(6) Place the fiberglass cloth on aluminum foil.
(7) Pour the fiberglass resin into a clean container.
(8) Mix the appropriate amount of hardener and
resin. Follow the manufacturers instructions.
(9) Apply the hardener/resin mixture to both sides
of the fiberglass cloth.(10) Place the fiberglass cloth over the repair sur-
face area. Next, place the aluminum foil over the
cloth. Use a plastic spreader to smooth-out the cloth
and resin. Use firm pressure to remove air bubbles
and to smooth-out the cloth.
(11) Allow the resin to cure.
(12) Smooth-out the surface area to the contour of
the hard top with a 50-grit disc.
(13) Apply plastic filler to complete the repair. Fin-
ish smoothing the surface area with 80-grit paper.
(14) Repeat the previous step on the inside surface
area of the hard top.
(15) Featheredge the repaired surface area.
(16) Prime the repaired surface area with Ditzler
Epoxy Chromate Primer (DP-40/401), or an equiva-
lent product.
(17) Apply surface primer to the surface area.
(18) Sand the surface area for paint preparation.
After sanding, re-prime the surface area, if necessary.
(19) Prime the surface area for the color coat.
(20) Color coat the repaired surface area.
FRACTURE REPAIR
(1) Use a grinder to remove the paint (from both,
the inner and outer surface areas of the hard top)
and to outline the damaged area.
(2) Stop-drill the crack(s) with a 3-mm (1/8-in) di-
ameter drill bit.
(3) Bevel the edges of the crack(s) on both sides
with a rotary file.
The edges should be beveled on the inside
and outside of the top to ensure sufficient sur-
face area for good bonding.
(4) Complete the repairs with fiberglass cloth and
resin as described above in the hard top hole repair
procedure.
TEXTURED PAINT REPAIR
The textured paint applied to hard tops is available
from Mopar Parts sources. The paint supplied will
duplicate the original texture on the hard top.
SOFT TOP SERVICE INFORMATIONÐYJ
The soft top fabric consists of the top cover and the
side and rear curtains (Fig. 4). The top cover is sup-
ported by a tubular bow (frame) and is attached to
the upper side retainers (above the doors) with
snap-on retainers (Fig. 5).
Fig. 3 Wire Harness Connection
JEXTERIOR COMPONENTSÐYJ 23 - 127

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JEEP YJ 1995 Service And Repair Manual Fig. 4 Soft Top Cover, Curtains and Windows
Fig. 5 Soft Top Bow, Spreader Bar and Retainers
23 - 128 EXTERIOR COMPONENTSÐYJJ

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JEEP YJ 1995 Service And Repair Manual SOFT TOP SERVICEÐYJ
REMOVAL
(1) Detach the snap-on retainers from the upper
side retainers (Fig. 4 and 6).
(2) Slide the upper side retainer lock forward.
Next, disengage the lock from the pin and re

Page 2048 of 2158

JEEP YJ 1995 Service And Repair Manual (15) Slide the center bow legs out of the lower side
retainers and remove the top cover from the vehicle.
Fig. 10 Releasing Spreader Bar Tension
Fig. 11 Rear Curtain Stowed
Fig. 12 Detaching Rear Corn

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