JEEP WRANGLER User Manual
Jeep Wrangler
Diagnosis & Repair Manual
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.
9. Generally, a car wash is the preferred method to diagnose a vehicle.
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.
READ FIRST READ FIRST
i
Diagnosis Road Map
p
r
(Pag
JK Hard/Soft Top
Water is on center of Instrument
Panel / Shifter
Freedom Top
(Pages 6-11)
Area of leaks
Repair Procedures
Water is on door trim panel or
Instrument Panel at A-pillar
Windshield Header
Seal
(Pages 1-2)
Door Fit
(Page 3)
A-Pillar
Mucket/Foam
(Pages 4-5)
Water at Rear Hard Top Panel /
B-
illa
Door Primary
Seal
Hard Top Seal
(Pages 12-14)
B-Pillar
Mucket/Foam
-
Water is on front carpet
Rear Wheel Flare
Holes
es 17-18)
Cowl Side Panel
(Pages 19-20)
ii
Table of Contents
I. Diagnosis Road Map i
II. General Notes ii
III. Water leak on Door Trim or Instrument Panel
a) Repair procedure for Windshield Header Seal 1-2
b) Repair procedure for Door Fits 3
c) Repair procedure for A-pillar mucket/foam 4-5
IV. Water leak on Instrument Panel/Console Center
a) Repair procedure for Freedom Panel Seal 6-11
b) Repair procedure for Freedom Panel latches 11
V. Water leak at B-plr
a) Repair procedure for Hard Top Seal 12-14
b) Repair procedure for B-pillar Mucket 15-16
VI. Water leak on front carpet
a) Repair procedure for rear wheel flare hole 17-18
b) Repair procedure for cowl side leaks 19-20
VII. Appendix
a) Foam Kit 21
b) Replacement part numbers 22
iii
Windshield Header Seal Repair Procedure
AREA OF LEAK:
• This repair procedure is applicable
when water is evident on the:
o Door trim panel
or
o Instrument panel (a-pillar)
STEP 1: Remove Header Seal
• Figure 1
STEP 2: Remove/Clean Surface
• Remove all butyl and tape residue
• A rubber wheel bit can be used
• Clean surface with 3M adhesive
cleaner
• Alcohol wipe entire surface and allow
to dry
Labor Op. Code: 235135
Figure 1
Figure 2
1
Windshield Header Seal Repair Procedure
STEP 3: Install Butyl
• NOTE: This operation is only
applicable for vehicles built before
6/1/2008. Vehicles built after this
date, should already have sealer
present in this area.
• Install 4mm butyl (68027813AA) as
shown (Figure 4)
• Make sure to fill in all holes, wrinkles
and step offs to allow for a smooth
surface to bond the tape/butyl from
the new seal
• NOTE: Excessive amount of butyl
can cause transition voids/leaks.
Make sure to smooth out butyl.
STEP 4: Install Seal
• Locate and install new seal, Pt #:
55397454AE
• Remove release tape and pressurize
seal firmly in contact with header
sheet metal to smooth out adhesive
tape and butyl, starting at the ends
and working toward the center. A
small roller or firm finger pressure
should be used to insure the tape is
adhered completely from side to side,
THIS STEP IS CRITICAL
Where to
place butyl
Figure 3
Butyl
Figure 4
Line seal
up here
Labor Op. Code: 235135
Critical area to pressurize
Figure 5
2
Door Fit Repair Procedure
AREA OF LEAK:
• This repair procedure is applicable
when water is evident on the:
o Door trim panel
or
o Instrument panel (a-pillar)
STEP 1: Door Gap Checks
• Measure door gaps
• The specifications are as follows:
• The gap spec. is 5.0 +/- 2.0 mm
• The flush spec. is 0.0 +/- 2.0 mm
• If the door fit is not to spec, proceed
to Step 2
STEP 2: Adjust Doors
• Adjust the door gap and flushness as
described in DealerConnect>
TechCONNECT under: Service info>
23 – Body> Body Structure> Gap and
Flush> Specifications Service Manual
STEP 3: Replace Door Primary Seal
• If the doors are adjusted, the door
seal must be replaced
• Part #: 55395274/5AN
Figure 6
Labor Op. Code: 230010
Figure 7
3
A-Pillar Foam/Mucket Repair Procedure
AREA OF LEAK:
• This repair procedure is applicable
when water is evident on the:
o Door Trim Panel
STEP 1: Header Mucket
• NOTE: This issue/repair applies to
both hard and soft top vehicles
• Inspect the header seal mucket for
the seal rolled under the freedom
panel or side rail. (Figure 8)
• If the seal is folded under, remove the
freedom panel or side rail and reinstall making sure not to distort the
mucket (Figure 9)
Labor Op. Code:
BAD
Figure 8
Figure 9
GOOD
4
A-Pillar Foam/Mucket Repair Procedure
STEP 2: A-Pillar Foam
• NOTE: This issue/repair applies to
both hard and soft top vehicles
• Inspect the freedom panel or side rail
for damaged/missing foam
(Figure 10)
• If the foam is damaged or missing,
replace the foam using the foam kit
(68026937AB)
STEP 2: Foam Installation
• Install the foam to the freedom panel
as shown in Figure 12
• The foam installation is similar for
the soft top rail
BAD
Figure 10
GOOD
Figure 11
Labor Op. Code:
RH Panel
Shown
Figure 12
5
B-Pillar Mucket/Foam Seal Repair
AREA OF LEAK:
• This repair procedure is applicable
when water is evident on the:
o Instrument panel (Center)
or
o Console / Shifter
RIGHT HAND FREEDOM PANEL
STEP 1: Seal Removal
• Remove seal on Right panel
STEP 2: Tape and Butyl Removal
• Remove tape and butyl residue from
panel
• A rubber wheel bit can be used
• Clean Seal Surface with: 3M General
Purpose Adhesive Cleaner or
Products Acrysol, (if available) and
allow to dry completely
• Wipe seal surface with alcohol and
allow to dry completely.
Labor Op. Code:
Kent
Figure 13
Figure 14
Figure 15
6
B-Pillar Mucket/Foam Seal Repair
R
R
STEP 3: Butyl Installation
• Place right hand freedom panel
upside down on a covered surface to
prevent scratching
• Apply 4 mm diameter Butyl, Pt #
68027813AA, to Rear Notch (Figure
17)
• Note: Follow groove between panels
and push butyl firmly in place
• Apply 4 mm diameter Butyl
68027813AA, to Front Notch
(Figure 18)
• Note: Follow groove between panels
and push butyl firmly in place
, Pt #
REA
FRONT
15mm
Figure 16
REA
20mm
15mm
Figure 17
FRONT
20mm
Labor Op. Code:
Figure 18
7
B-Pillar Mucket/Foam Seal Repair
R
STEP 4: Seal Installation
• Keep freedom panel upside down for
the initial installation of the seal
• Remove tape liner from seal
NOTE: Secure the end molds first, then
finish with the middle of the seal
Rear Seal Mold
• Align REAR edge of NEW seal, Pt #
55397095AG to Right Freedom Panel
Notch.
• Compress butyl by installing seal in
direction of arrows (Figure 20)
• Note: No gap between installed seal
and outer edge of freedom panels.
(Figure 20)
Front Seal Mold
• Align FRONT edge of NEW seal, Pt #
55397095AG to Right Freedom Panel
Notch
• Compress butyl by installing seal in
direction of arrows (Figure 21)
• Note: No gap between installed seal
and outer edge of freedom panels.
(Figure 21)
REA
FRONT
Figure 19
Rear Mold
Figure 20
Labor Op. Code:
Figure 21
Front Mold
8
B-Pillar Mucket/Foam Seal Repair
STEP 5: Pressurize Seal
• Flip panel back over to complete the
seal installation
• Locate seal cross car against the
middle rib in the freedom panel and
pressurize starting at the ends and
working toward the center
• A small roller or firm finger pressure
should be used to insure the seal
tape is adhered from front to rear,
THIS STEP IS CRITICAL
STEP 6: Install foam at Front
• Install GREY 30 X 75 mm Foam from
kit (68026937AB) along trim lines of
flame tip (Figure 24)
• NOTE: Make sure foam covers butyl
completely
This photo is for
reference only. Panel
was cut to show rib.
Locator rib in panel
Figure 22
Figure 23
Labor Op. Code:
Front of panel
Figure 24
9
B-Pillar Mucket/Foam Seal Repair
STEP 7: Install foam at Rear
• Install BLACK 30 X 75 mm Foam from
kit (68026937AB) along trim lines of
flame tip (Figure 25)
• NOTE: Make sure foam covers butyl
completely
Figure 25
LEFT HAND FREEDOM PANEL
STEP 8: Install butyl at Rear
• Place Left hand freedom panel
upside down on a covered surface to
prevent scratching
• Add 4mm diameter butyl,
(68027813AA) to rear inboard corner
groove (Figure 27)
• Note: Push butyl firmly into groove
between panels until flush
REAR
Figure 26
70 mm
25 mm
Figure 27
Labor Op. Code:
10
B-Pillar Mucket/Foam Seal Repair
STEP 9: Install foam at Rear
• Add 30 X 75 mm Black Foam from Kit
(68026937AB) to cover butyl
(Figure 28)
• NOTE: Make sure foam covers butyl
completely
STEP 10: Install front latches
• NOTE: This applies to both Right and
Left panels
• If the vehicle MDH is prior to 12/07/07,
replace the front latches with part
number 68004562AB (Figure 29)
Labor Op. Code:
Figure 28
Figure 29
11
B-Pillar Mucket/Foam Seal Repair
AREA OF LEAK:
• This repair procedure is applicable
when water is evident on the:
o B-pillar roll bar
o B-pillar trim
o Freedom panel screw holes
NOTE: Water that enters anywhere along
the hard top seal can travel over to the Bpillar and leak from the hard top
STEP 1: Inspect Hard Top Seal
• Inspect for any gaps between the
seal and hard top (Figure 30,31)
Figure 30
Labor Op. Code:
Figure 31
12
B-Pillar Mucket/Foam Seal Repair
STEP 1: Inspect Hard Top Seal
(cont.)
Inspect the end molds for poor
•
installation (Figure 32)
BAD GAP
•
Inspect underneath the seal for any
skips with the tape/butyl along the
entire seal (Figure 34 & 35).
Figure 34
GOOD GAP
Figure 32
Figure 33
TAPE SKIP
Figure 35
Labor Op. Code:
13
B-Pillar Mucket/Foam Seal Repair
STEP 2: Replace Hard Top Seal
If there are multiple skips or the leak
cannot be stopped, replace seal.
Remove all tape/butyl and clean with
alcohol prior to installation
A rubber wheel bit can be used to
remove the tape
Pre-apply butyl (68027813AA) on
hard top prior to installing the seal
(Figure 36)
It is critical that then end molds are
installed correctly and sufficient
pressure is applied to wet out the
butyl/tape (Figure 36)
Labor Op. Code:
Apply butyl
as shown
Pressurize
Figure 36
2mm
underflush
Figure 37
14
B-Pillar Mucket/Foam Seal Repair
AREA OF LEAK:
• This repair procedure is applicable
when water is evident on the:
o B-plr trim or seat
NOTE: This repair applies to 4 door hard
top or soft top models
STEP 1: Inspect mucket detail
Inspect the mucket for a rolled under
condition (Figure 38)
Inspect the mucket for a missing
drain hole
STEP 2: Replace the mucket detail
If either of these conditions exist,
replace the mucket detail
(Part #:55395708/9AE)
Reinstall the panel or side rail making
sure not to distort the mucket
BAD
Figure 38
Labor Op. Code:
GOOD
Figure 39
15
B-Pillar Mucket/Foam Seal Repair
STEP 3: Inspect Freedom Panel for
damaged or missing foam
• If the foam is damaged or missing,
replace the foam using the foam kit
(68026937AB)
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
NOTE: This foam is in addition to the foam
that is already on the panel
RH Panel
Shown
Figure 40
FOAM
Figure 41
Labor Op. Code:
16
Rear Wheel Flare Hole Repair
AREA OF LEAK:
• This repair procedure is applicable
when water is evident on the:
o Front floor (wet carpet)
o Under seat
NOTE: This leak can be diagnosed by
applying a hose to the upper rear flare and
inspecting for water traveling along the
floor to the front
STEP 1: Remove Rear Flare
STEP 2: Replace/Install Patch
Hole :
1
NOTE: Vehicles built prior to 5/28/08 will
require this repair
• Inspect the body for missing or mis-
aligned tape over the hole as seen in
Figure 43
Add/Replace a tape patch over the
hole
Hole:
NOTE: Vehicles built prior to 5/01/09 will
require this repair
• Inspect the body for missing or mis-
Add/Replace a tape patch over the
Labor Op. Code:
2
aligned tape over the hole as seen in
Figure 43
hole
Leak Path
Figure 42
1
2
Figure 43
17
Rear Wheel Flare Hole Repair
Hole:
NOTE: Vehicles built prior to 7/22/08 will
require this repair
• Cut the BLACK 30 x 75 foam from the
Make sure the foam does not extend
Re-install flare
3
foam kit (68026937AB) in half and
apply over this hole (Figure 45)
past the flare trim line (appearance
issue)
Figure 44
3
Figure 45
Labor Op. Code:
18
Cowl Side Panel Repair
AREA OF LEAK:
• This repair procedure is applicable
when water is evident on the:
o Front floor (wet carpet)
NOTE: These leaks can be diagnosed by
applying a hose in the cowl panel (Figure
47).
Leak area
Figure 46
Apply hose
in cowl area
Labor Op. Code: 235001
Figure 47
19
Cowl Side Panel Repair
Condition 1: Mastic patches/Plugs
Repair 1: Replace patch/plug
Condition 2: Check strap bracket
Repair 2: Remove bracket and apply a butyl
to holes
Condition 3: Seam sealer skips
Repair 3: Apply clear sealer
(part #: 04467708) to skip
Condition 4: Scuff trim foam damaged/missing
Repair 4: Replace trim clips
Condition 5: Antenna grommet not seated
Repair 5: Re-install grommet
Labor Op. Code: 235001
_-
1
5
1
3
1
Figure 48
1
4
3
2
20
Appendix
Foam Kit: 68026937AB
A/B-Pillar Foam
Used on Pages (5,16,)
30 mm x 75mm BLACK Foam
Used on Pages (10,11)
30 mm x 75mm GREY Foam
Used on Pages (9,16)
Labor Op. Code:
21
Appendix
Jeep Wrangler
Replacement Parts List
Part # Part Name Page(s)
68027813AA Butyl 2,7,10,14
04467708 Clear Sealer 20
68026937AB Foam Kit 5,9-11,16
55397454AE Windshield Header Seal 2
55395274/5AN Front Door Primary Seal 3
55395708/9AE B-Pillar Mucket 15
55397095AG Freedom Panel Seal 8
55397046AF Hard Top Seal 4DR 14
55397058AF Hard Top Seal 2DR 14
68004562AB Freedom Panel Latch 11
Labor Op. Code:
22
JK Freedom Top
-Center Front-
Water Leak Repair
Reference TSB # 23-020-08 As Required for additional Repair Information
10/14/2008 1
4
5
6
1
2
3
1.Windshield header seal
2.Windshield to cowl seal
3.Front door weatherseal
4.B pillar mucket
5.Hard top seal
Outside View
10/14/2008 2
6.Center freedom panel seal
9
7
12
9
8
10
11
13
7. Left Freedom Panel
8. Panel to Panel Latches
9. Panel to Hard Top Latches
10. Hard Top
11. Right Freedom Panel
12. Latch & Base Assembly 68004562AB
Inside View
10/14/2008 3
13 Sport Bar Thumb Screws
*Please note:
This package addresses water leaks that come from
inside the vehicle when the door is closed.
This package does not address
water that drips into the Vehicle
when the door is open.
This is a normal condition!
10/14/2008 4
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