Removal; Installation; Door Removal; Adjustments Adjustment - Jeep KJ 2005 Service Manual

23 - 28 DOORS - REAR
DOOR

REMOVAL

(1) Disconnect the door wire harness electrical con-
nector at the b-pillar.
(2) Disconnect the check strap from the b-pillar.
(Refer to 23 - BODY/DOORS - REAR/CHECK STRAP
- REMOVAL)
(3) Support the door with a suitable lifting device.
NOTE: The epoxy washers should not be removed
from the hinge. If the washers are removed the door
may have to be re-adjusted.
(4) Remove the nuts attaching the door hinges to
the door. (Fig. 2)
Fig. 2 HINGES
1 - DOOR
2 - HINGES
3 - EPOXY WASHERS (2) (NOT REMOVABLE)
4 - NUTS

INSTALLATION

(1) Support the door with a suitable lifting device
and install the door onto the b-pillar.
(2) Install the nuts, washers and tighten to 23
N·m (17 ft. lbs.).
(3) Connect the door wire harness electrical con-
nector.
(4) Connect the check strap to the b-pillar. (Refer
to 23 - BODY/DOORS - REAR/CHECK STRAP -
INSTALLATION)
(5) Adjust the door as necessary. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
ADJUSTMENTS
ADJUSTMENT
NOTE: For vehicles equipped with four doors, it is
recommended that you adjust the rear door before
adjusting the front door.
• Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
• During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper fasteners to hold the
door with final torque of the fasteners occurring
after correct door positioning is achieved.
FORE/AFT
NOTE: Fore/aft (lateral) door adjustment is done by
loosening the hinge to the hinge pillar fasteners
one hinge at a time and moving the door to the cor-
rect position.
(1) Support the door with a suitable lifting device.
(2) Loosen the hinge to hinge pillar fasteners.
(Refer to 23 - BODY/DOORS - REAR/HINGE -
REMOVAL)
(3) Adjust the door to the correct position. (Refer
to 23 - BODY/BODY
FLUSH - SPECIFICATIONS)
(4) Tighten to hinge pillar fasteners to 28 N·m (21
ft. lbs.). (Refer to 23 - BODY/DOORS - REAR/HINGE
- INSTALLATION)
NOTE: Use a suitable body sealer on the hinge to
body mating surfaces.
UP/DOWN
NOTE: Up/down door adjustment is done by loosen-
ing either the hinge to the hinge pillar fasteners or
the hinge to door fasteners and moving the door to
the correct position.
NOTE: When adjustment of the door requires the
loosening of the door to hinge fasteners, it will be
necessary to separate the epoxy bonded washers
with a chisel or other suitable tool.
STRUCTURE/GAP AND
KJ