XJ4IV
05-11-2011, 10:42 PM
I have been pondering the whole rear doors removal for a few months now. so today having had ALL the items sitting on the shelf for a few weeks now I decided that I need to just bite the bullet and get to cutting.
Im doing the passenger side due to the slight modification that is needed that the driver side doesnt need...
Here is the before pic
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG305.jpg
First off open the front door to access the hinge of the rear door to see this...
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG296.jpg
remove the little plastic cover to reveal this
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG297.jpg
notice that you can now see the hinge bolts through the holes that jeep offered to us... YAY!
Anyhow now on to the door removal
These bolts are a T-40 Torx bit... good luck!
Now that the door is off you have the remaining hinge,
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG298.jpg
notice that the hinge pin on this door is mounted from the bottom so this pin must be driven out but be careful and save this one as you WILL need it to rebuild the hinges
here are the hinge pins after they are removed
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG300.jpg
once you get those out
make sure you cut the bottom of the hinges off sooooo you can remove the doors
Here is when you flip the pins to the top
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG301.jpg
Next item to be attended to is this little sleeve in the hinge... this makes it VERY difficult to remove the doors SO we need to bore that sleeve out... just grab a drill bit of the same size and wallow it out until it the sleeve comes out
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG299.jpg
this is what it looks like when out
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG293.jpg
once the door is off you can the put them back on but dont tighten the bolts just yet!
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG292.jpg
also notice that the backing bracket is also modified to make removal and re-install easier
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG303.jpg
the last cut needed to make things easier
is the cut the lower hinge pin the same thickness as the part of the hinge you removed THIS will help you install by inserting the top hinge pin first then lower the door a TAD then just align the lower pint and let it drop into place.
here is the last step... drop the door back into place remember that your hinge bolts are still loose then gently close the door all the way and make sure the body lines all match up nicely ... once they are again use these access holes to hit two of the 3 bolts on each hinge to hold it in place and set the alignment for the doors.
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG304.jpg
Once you get those two bolts per hinge torqued down then open the door back up and tighten the remaing two bolts and your done...
final appearance
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG305.jpg
looks as though nothing changed!
If I left anything out please ask and I will fill it in as well...
as for the wires in the doors... I went to radio shack and found a plug that is a 4 wire that I will eventually just splice in and the remaining wire just make a plug out of a male and female pieces.
Im doing the passenger side due to the slight modification that is needed that the driver side doesnt need...
Here is the before pic
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG305.jpg
First off open the front door to access the hinge of the rear door to see this...
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG296.jpg
remove the little plastic cover to reveal this
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG297.jpg
notice that you can now see the hinge bolts through the holes that jeep offered to us... YAY!
Anyhow now on to the door removal
These bolts are a T-40 Torx bit... good luck!
Now that the door is off you have the remaining hinge,
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG298.jpg
notice that the hinge pin on this door is mounted from the bottom so this pin must be driven out but be careful and save this one as you WILL need it to rebuild the hinges
here are the hinge pins after they are removed
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG300.jpg
once you get those out
make sure you cut the bottom of the hinges off sooooo you can remove the doors
Here is when you flip the pins to the top
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG301.jpg
Next item to be attended to is this little sleeve in the hinge... this makes it VERY difficult to remove the doors SO we need to bore that sleeve out... just grab a drill bit of the same size and wallow it out until it the sleeve comes out
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG299.jpg
this is what it looks like when out
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG293.jpg
once the door is off you can the put them back on but dont tighten the bolts just yet!
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG292.jpg
also notice that the backing bracket is also modified to make removal and re-install easier
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG303.jpg
the last cut needed to make things easier
is the cut the lower hinge pin the same thickness as the part of the hinge you removed THIS will help you install by inserting the top hinge pin first then lower the door a TAD then just align the lower pint and let it drop into place.
here is the last step... drop the door back into place remember that your hinge bolts are still loose then gently close the door all the way and make sure the body lines all match up nicely ... once they are again use these access holes to hit two of the 3 bolts on each hinge to hold it in place and set the alignment for the doors.
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG304.jpg
Once you get those two bolts per hinge torqued down then open the door back up and tighten the remaing two bolts and your done...
final appearance
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG305.jpg
looks as though nothing changed!
If I left anything out please ask and I will fill it in as well...
as for the wires in the doors... I went to radio shack and found a plug that is a 4 wire that I will eventually just splice in and the remaining wire just make a plug out of a male and female pieces.