Jeep Repair Manual JK
Jeep Repair Manual JK
Jeep Repair Manual JK
Water Leaks
Rev. A
General Notes
1. This manual applies to all Jeep models: 2/4 door & Hard/Soft Top
2. Before testing the vehicle, perform a review of the top system. Make sure all the latches
are engaged, none of the top seals are puckered or distorted, the door seals are
installed correctly, the tops are not out of alignment, etc.
3. Each leak area can have multiple root causes, as noted in the diagnosis tree. It is
important to water test each repair before starting the next.
4. If a leak cannot be reproduced, it is due to the period of time the vehicle is under wet
conditions. Some leaks may take hours before leaking.
5. If a leak cannot be reproduced, apply all the repairs to the applicable areas as noted in
the diagnosis road map.
6. When the door is open, there is water run off from the roof that can soak the carpet. Be
sure to explain to the customer that this cannot be fixed. This is an unfortunate
condition with this type of vehicle, similar to convertibles.
7. It is important to understand where the leak ENDS up when diagnosing the vehicle.
Where the leak ends up, does not always explain where the leak originates. Refer to the
diagnosis tree when determining which repairs to perform.
8. This repair procedure does NOT cover every possible water leak on the Jeep Wrangler.
The issues identified in this document are the major leaks that show up in the field.
10. If a hose is required, place on the top of the vehicle facing forward making sure water is
getting to all areas. Do NOT directly spray in the area of question. This can create a
“false” leak that cannot be fixed.
11. This manual is not intended to be a service manual. The content identifies the major
areas of water leaks, the critical characteristics of each area and how to repair them.
i
Diagnosis Road Map
JK Hard/Soft Top
Water is on center of Instrument Water is on door trim panel or Water at Rear Hard Top Panel / Water is on front carpet
Panel / Shifter Instrument Panel at A-pillar B-pillar
Freedom Top Windshield Header Hard Top Seal Rear Wheel Flare
(Pages 6-11) Seal (Pages 12-14) Holes
(Pages 1-2) (Pages 17-18)
ii
Table of Contents
VII. Appendix
a) Foam Kit 21
b) Replacement part numbers 22
iii
Windshield Header Seal Repair Procedure
AREA OF LEAK:
• Figure 1
Figure 1
STEP 2: Remove/Clean Surface
Figure 2
Labor Op. Code: 235135 1
Windshield Header Seal Repair Procedure
Figure 4
STEP 4: Install Seal
AREA OF LEAK:
• Part #: 55395274/5AN
Figure 7
Labor Op. Code: 230010 3
A-Pillar Foam/Mucket Repair Procedure
AREA OF LEAK:
BAD
Figure 8
GOOD
Figure 10
GOOD
Figure 11
RH Panel
Shown
Figure 12
Labor Op. Code: 5
B-Pillar Mucket/Foam Seal Repair
AREA OF LEAK:
Figure 13
Figure 15
Labor Op. Code: 6
B-Pillar Mucket/Foam Seal Repair
FRONT
Figure 16
• Apply 4 mm diameter Butyl, Pt #
68027813AA, to Rear Notch (Figure
17) REAR
20mm
15mm
Figure 17
• Apply 4 mm diameter Butyl, Pt #
68027813AA, to Front Notch
(Figure 18) FRONT
20mm
REAR
STEP 4: Seal Installation
Figure 19
Rear Seal Mold
Figure 20
Front Seal Mold
Front Mold
Figure 22
Figure 23
STEP 6: Install foam at Front
Front of panel
Figure 24
Labor Op. Code: 9
B-Pillar Mucket/Foam Seal Repair
Figure 25
Figure 26
• Note: Push butyl firmly into groove
between panels until flush
70 mm
25 mm
Figure 27
Figure 28
Figure 29
Labor Op. Code: 11
B-Pillar Mucket/Foam Seal Repair
AREA OF LEAK:
Figure 30
Figure 31
Labor Op. Code: 12
B-Pillar Mucket/Foam Seal Repair
STEP 1: Inspect Hard Top Seal • Inspect underneath the seal for any
(cont.) skips with the tape/butyl along the
entire seal (Figure 34 & 35).
• Inspect the end molds for poor
installation (Figure 32)
BAD GAP
Figure 34
Figure 32
Figure 35
Figure 33
Pressurize
Figure 37
AREA OF LEAK:
GOOD
Figure 39
Labor Op. Code: 15
B-Pillar Mucket/Foam Seal Repair
RH Panel
Shown
Figure 40
STEP 4: Add additional foam to
freedom panel
Add a piece of foam to the freedom
panel as shown in Figure 41. This
foam can be created by cutting the 30
x 75mm GREY foam in half from the
foam kit (68026937AB)
Figure 41
Figure 41
AREA OF LEAK:
Hole : 1
Hole: 2
Hole: 3
Re-install flare
Figure 44
Figure 45
AREA OF LEAK:
Leak area
Figure 46
Apply hose
in cowl area
Figure 47
Labor Op. Code: 235001 19
Cowl Side Panel Repair
1
Condition 3: Seam sealer skips
3 3
Repair 3: Apply clear sealer
(part #: 04467708) to skip 1
2
4
Condition 5: Antenna grommet not seated
Figure 48
Jeep Wrangler
Replacement Parts List