1995 JEEP YJ Service And Repair Manual

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Page 2049 of 2158

JEEP YJ 1995 Service And Repair Manual INSTALLATION
(1) If stowed at the rear of the vehicle, detach the
elastic straps that retain the top cover (Fig. 16).
(2) If not stowed, position the center bow legs an-
chor pins in the lower side re

Page 2050 of 2158

JEEP YJ 1995 Service And Repair Manual channel. Close the rear window curtain zippers and
attach the side snap-on retainers.
(16) Attach all the top cover snap-on retainers to
the upper side retainers located above both doors. As
necessary

channel. Close the rear window curtain zippers and
attach the side snap-on retainers.
(16) Attach all the top cover snap-on retainers to
the upper side retainers located above both doors. As
necessary, slide the mating half of the snap-on re-
tainers so that they will align with the snap-on re-
tainers on the top cover. Tuck the edge of the top
cover inside the side retainer.
(17) Install the door windows by inserting the re-
tainers into the door grommets. Attach the snap-on
retainers located along the bottom edge of the win-
dow to the door retainer.
SPORT BARÐYJ
REMOVAL
(1) Disconnect sound bar. Refer to Group 8F, Audio
Systems for removal and installation procedures.
(2) Remove the screws that attach the sport bar
base plates to the floor and wheelhouse panels (Fig.
1).
(3) Remove the retaining screws and bolts, and re-
move the side bars from the windshield frame and
the sport bar (Fig. 1 and 2).
(4) Carefully lift the sport bar upward and remove
it from the vehicle.
(5) If necessary, remove the pads and covers from
the sport bar.
INSTALLATION
(1) Clean the base plate contact surface areas on
the floor and wheelhouse panels.
(2) Apply epoxy chromate primer to the attaching
screw hole edges for protection against corrosion.
(3) Position the sport bar base plates on the floor
and wheelhouse panels with the screw holes aligned.
To prevent water seepage, apply 3M Drip-
Chek Sealant (or an equivalent product) to the
underside of all the screw heads before instal-
lation.(4) Apply sealant to the underside of each base
plate attaching screw head. Install and tighten the
screws to 42 Nzm (31 ft. lbs.) torque.
(5) Position the side bars at the windshield frame.
Tighten the screws to 32 Nzm (24 ft. lbs.) torque.and
at the sport bar. Install screws and bolts in the wind-
shield frame and the sport bar. Tighten the screws to
32 Nzm (53 ft. lbs.) torque.
(6) Position the side bars at the sport bar. Install
the bolts in the sport bar. Tighten the screws to 71
Nzm (53 ft. lbs.) torque.
(7) Install sound bar.
Fig. 20 Engaging Spreader Bar Lock
Fig. 1 Sport Bar
Fig. 2 Sport Bar-To-Side Bar Bolt
23 - 132 EXTERIOR COMPONENTSÐYJJ

Page 2051 of 2158

JEEP YJ 1995 Service And Repair Manual EXTERNAL SPARE/WHEEL TIRE CARRIERÐYJ
REMOVAL
(1) Remove the spare tire and wheel from the
wheel bracket (Fig. 3).(2) Remove the screws that attach the wheel
bracket to the tailgate.
(3) Disconnect CH

Page 2052 of 2158

JEEP YJ 1995 Service And Repair Manual DOORS
INDEX
page page
Beltline SealÐYJ........................ 142
Door Frame Glass Channel ReplacementÐYJ . . . 142
Door Weatherstrip Seal ReplacementÐYJ...... 142
Full-Metal Door Assist HandleÐY

DOORS
INDEX
page page
Beltline SealÐYJ........................ 142
Door Frame Glass Channel ReplacementÐYJ . . . 142
Door Weatherstrip Seal ReplacementÐYJ...... 142
Full-Metal Door Assist HandleÐYJ........... 136
Full-Metal Door HingesÐYJ................ 140
Full-Metal Door Key Lock CylinderÐYJ........ 139
Full-Metal Door Latch External Release
HandleÐYJ........................... 140
Full-Metal Door Latch Inside Release and Lock
HandleÐYJ........................... 137
Full-Metal Door LatchÐYJ.................. 140Full-Metal Door ServiceÐYJ................ 142
Full-Metal Door Trim PanelÐYJ.............. 137
Full-Metal Door Vent Window GlassÐYJ....... 137
Full-Metal Door WaterdamÐYJ.............. 137
Full-Metal Door Weatherstrip SealsÐYJ........ 141
Full-Metal Door Window Glass Regulator
HandleÐYJ........................... 136
Full-Metal Door Window Glass RegulatorÐYJ . . . 138
Full-Metal Door Window GlassÐYJ........... 139
Half-Metal Door Latch StrikerÐYJ............ 135
Half-Metal Soft Top DoorÐYJ............... 134
HALF-METAL SOFT TOP DOORÐYJ
REMOVAL/DISASSEMBLY
(1) Open the door.
(2) Disconnect the door restraint strap from the
pin (Fig. 1).
(3) Turn the window retaining sleeves 1/4 turn to
the left and pull them up and out of the door (Fig. 2).
(4) Remove the window from the door by detaching
the soft top-to-door snap fasteners and pulling the
window up and out of the door (Fig. 3).
(5) Remove the latch interior release handle (Fig.
4).
(6) Remove the assist handle.
(7) Remove the trim panel by detaching the retain-
ers around the perimeter of the trim panel (Fig. 4).(8) Remove the screws from the door latch handle,
disconnect the latch release rod and remove the han-
dle (Fig. 4).
(9) Remove the door latch screws (Fig. 4). Remove
the door latch with the rods attached.
(10) Remove the weatherstrip seal screws and
carefully remove the weatherstrip seal from door
edge (Fig. 5).
(11) Remove the retaining nuts from the door
hinge pivots and remove the door from the body (Fig.
1).
(12) Remove the retaining screws and the hinges
from the door.
ASSEMBLY/INSTALLATION
(1) Install the hinges and the retaining screws on
the door. Tighten the screws securely.
Fig. 1 Half-Metal Soft Top Door
Fig. 2 Window Retaining Sleeves
23 - 134 DOORSÐYJJ

Page 2053 of 2158

JEEP YJ 1995 Service And Repair Manual (2) Position the door at the vehicle, insert the
hinge pivots in the hinge receptacles and install the
retaining nuts (Fig. 1). Tighten the nuts securely.
(3) Install the weatherstrip seal on the door

Page 2054 of 2158

JEEP YJ 1995 Service And Repair Manual FULL-METAL DOOR WINDOW GLASS REGULATOR
HANDLEÐYJ
REMOVAL/INSTALLATION
The window glass regulator handle is attached to
the splined regulator shaft with an internal hex-head
screw (Fig. 8).
(1) To rem

Page 2055 of 2158

JEEP YJ 1995 Service And Repair Manual (3) Close the jaws on the latch.
(4) Push the lock-to-latch rod forward toward the
inside release handle. Check to ensure the lock lever
on the latch is in the unlocked position.
(5) Position the thre

(3) Close the jaws on the latch.
(4) Push the lock-to-latch rod forward toward the
inside release handle. Check to ensure the lock lever
on the latch is in the unlocked position.
(5) Position the threaded end of the lock rod over
the lever clip on the latch and push the rod into the
lock lever clip (Fig. 9). The lock lever should have a
full sweep of travel when activated by the inside con-
trol button. It should not bind or be stiff.
(7) Position the threaded end of the release lever
rod over the release lever clip on the latch and push
the rod into the release lever clip. The release lever
on the latch should be resting against the stop with
no preload after the rod is engaged in the retaining
clip. Visual observation will reveal any preload. If
preload is noted, disconnect the release lever rod and
install it again to eliminate the preload.
(8) Pull up on the outside handle release rod to po-
sition it as far up as possible and push the rod into
the release lever clip on the latch. The release lever
on the latch should be resting against stop with no
preload after the rod is engaged in the retaining clip.
(9) Close the latch jaws.
(10) Activate the inside lock control button. It
should not bind or be stiff, if either condition exists,
the latch should replaced.
(11) With the inside lock control button in the un-
lock position, pull the inside door handle to open the
jaws on the latch and close the door.
FULL-METAL DOOR LATCH INSIDE RELEASE AND
LOCK HANDLEÐYJ
REMOVAL
(1) Remove the retaining screw (Fig. 8).
(2) Pull the handle outward and detach the lock
and release rods from handle (Fig. 9).
(3) Remove the handle from the upper trim panel
(Fig. 8).
INSTALLATION
(1) Position the handle adjacent to the rods in the
upper trim panel opening and attach the rods to the
handle (Fig. 9).
(2) Position the handle in the upper trim cover and
install the retaining screw Fig. 8).
FULL-METAL DOOR TRIM PANELÐYJ
The door interior trim panels are covered with a vi-
nyl material (Fig. 8). They are attached to the door
inner panel rail retainer and with plastic clips in-
serted into holes in the door inner panel.
REMOVAL
(1) Remove the door assist handle (Fig. 8).
(2) Remove the window glass regulator handle
(Fig. 8).
(3) Remove the door latch release handle and the
upper trim panel (Figs. 8 and 9).
(4) Pry the lower trim panel-to-door retainers (lo-
cated around the perimeter of the panel) outward
and remove the panel (Fig. 8).
INSTALLATION
(1) Position the lower trim panel on the door inner
panel and insert the retainers in the holes in the
door inner panel.
To prevent creasing the trim panel vinyl
cover, do not hammer or exert excessive force
on the retainers.
(2) Install the upper trim panel and the door han-
dle.
(3) Install the window glass regulator handle (Fig.
8).
(4) Install the door assist handle.
FULL-METAL DOOR WATERDAMÐYJ
The waterdam is attached to the door inner panel
with adhesive and tape (Fig. 10).
REMOVAL/INSTALLATION
(1) To remove a waterdam, insert a putty knife be-
tween it and the door inner panel.
(2) When installing a waterdam, ensure that lower
portion of
waterdam is tucked inside the door panel at the ac-
cess opening.
FULL-METAL DOOR VENT WINDOW GLASSÐYJ
REMOVAL
(1) Remove the door trim panel and the waterdam
(Fig. 8 and 9).
(2) Lower the door window glass to the down-stop
position.
(3) Remove the division channel upper attaching
screw and the lower adjustment screw (Fig. 11).
Fig. 9 Inside Door Handle and Rods
JDOORSÐYJ 23 - 137

Page 2056 of 2158

JEEP YJ 1995 Service And Repair Manual (4) Detach the front three inches of weatherstrip
seal from the door upper frame. Lower the division
channel and tilt it toward the rear of the door.
(5) Remove the vent window glass from the door
fra

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