NUMBER: DATE: Mar. 19, 1999

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1 NUMBER: GROUP: Body DATE: Mar. 19, 1999 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission of DaimlerChrysler Corporation. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER , DATED AUG. 14, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE TECHNICAL SERVICE BULLETIN BOUND MANUAL FOR THE RESPECTIVE MODEL YEAR. IT ADDS 1999 MODELS AND A HEATER A/C COWL AIR INLET COVER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. SUBJECT: Water Leak Diagnostic/Repair Procedure OVERVIEW: This bulletin is intended to assist in identifying water leak entry points by highlighting areas where leaks are likely to occur based on the experience gained during the development of the vehicle. A thorough water test is required and the test will often readily show entry points which require repair. This bulletin is broken down by specific areas and provides illustrations as to where to look in these areas. The repair methods may vary depending on the situation you encounter but we have provided some recommendations for sealing the effected areas. MODELS: **1999** (TJ) Wrangler PARTS REQUIRED: ** AA Heater A/C Air Inlet Cover** AR AF Door Seal - left AR AF Door Seal - right AR AC Foam Seal AR AE W/S to Cowl Seal AR AB W/S A Pillar Molding(RH) AR AB W/S A Pillar Molding(LH) AR AA Retainer, Cowl Grille screw AR ** AF** Seal - Liftgate Glass AR AC Seal - Tailgate AR AA Foam Seal - Door Rail Upper(RH) AR AA Foam Seal - Door Rail Upper(LH Form TSB-003 Rev. 1.05

2 REPAIR PROCEDURE: This bulletin involves locating and sealing seams, body plugs, grommets and seals in the following areas: A. Floor area - Front, Driver and Passenger sides B. Floor Area - Rear Floor and Cargo Area C. Windshield D. Doors E. Cowl F. Hard Top G. Soft Top H. Tailgate A. Floor Area 1. Inspect all of the bulkhead grommets and plugs both in the passenger compartment and under the hood (see Figure 1). Replace any missing plugs or grommets. Make sure all plugs and grommets are fully seated. If water tracks are present inside the vehicle, seal the area with clear seam sealer or RTV sealant. Clean and seal the seam between the brake booster reinforcement plate and the bulkhead with clear RTV sealant as shown. Spray water directly on the bulkhead from in the engine compartment. This area receives heavy road spray and is often overlooked when diagnosing water leaks. Seal any suspect areas such as holes for heater a/c plumbing. FIGURE 1

3 Inspect the kick panel areas (Figure 2). Remove the speaker grilles and speakers. This area is visible through the speaker opening. Carefully check the antenna plug on vehicles shipped without a radio. Seal the plugs with clear seam sealer or RTV. Seal the body seams with clear seam sealer or aerosol sealer such as Kent Industries Aerosol Leak Check or equivalent. FIGURE 2 B. Rear Floor Area 1. Check the seam between the wheel house and the body for sealer skips or water traces. Seal the effected area with seam sealer or aerosol leak check. Inspect for the presence of a clear plastic film covering the body fixture hole under the rear wheel flare (see Figure 3). If the film is missing, cover the hole with a piece of aluminum body repair tape and install the flare. C. Windshield FIGURE 3 1. Water test the windshield and seal as required if leaks occur at the glass to windshield frame.

4 Removal of the cowl grille will facilitate viewing the windshields frame to body seam. If leaks are present here, fold the windshield down and install a new cowl seal, p/n AE (Figure 4). Replace the plastic screw retainers for the cowl grille (p/n AA). FIGURE 4 3. If leaks are present at the A pillar, windshield angle adjustment may be required. See the Door section of this bulletin for the adjustment procedure. 4. Apply a small bead of clear sealer to the vertical edge of the windshield hinge. This will prevent water from seeping behind the hinge where there are open holes used during the manufacturing process. D. Doors 1. Inspect the A pillar area. The gap between the door frame and windshield must be parallel. If a V gap is present, the windshield angle must be adjusted. This is accomplished by loosening the bolt at the rear of the sport bar side support. Loosen the torx head bolt on the windshield hinge closest to the hinge pivot point. Adjust the windshield angle to correct the gap and tighten the bolts at the hinge and side support bar to lock the adjustment. 2. Water test the door area. If any water is leaking around the full hard door weather seal, replace the seal with p/n AF right or AF - left. Inspect the door fit to the body. Adjust the door to allow even gap all the way around the perimeter. 3. Inspect the upper door frame where it contacts the seal. Make sure that the contact area is smooth to provide a good sealing area. Apply a clear seam sealer to any rough areas as required.

5 If water is leaking between the door trim panel and the inner door, there are several areas to inspect. Make sure that the water dam is in place and is in good shape. Replace the water dam if required. Inspect for the presence of a butyl patch on the outside handle latch rod. The patch must cover the top screw of the bracket. Make sure that the foam pads are present at the trim panel locating pins and that they seal against the door. Make sure that the trim panel retainers have butyl sealer over them to seal against the door. 5. Inspect the A pillar joint at the cowl side in the door opening for a smooth sealing surface. Later vehicles contain a body colored patch in this area. If no patch is present and leaks are suspect in this area, apply a clear sealer to this area to smooth this joint. (See Figure 6). FIGURE 6 E. COWL 1. Remove the cowl grille and inspect the cowl area. Seal all seams with RTV. 2. Seal the entire perimeter of the heater A/C air inlet with RTV to assure that no water will enter the heater A/C housing through this area.

6 **Drill three, 3/16 in. (4.5 mm) holes in the cover in the areas shown in Figure 7. Position the cover over the air inlet as shown and using the cover as a template, mark the holes. Drill three 1/8 in (3 mm) holes into the cowl sheet metal. Apply a bead of RTV around the perimeter of the flange to seal the flange to the cowl sheet metal and attach the cover the cowl using 5/8 inch long (16 mm) #8 sheet metal screws.** **FIGURE 7** 4. To prevent any excess water from entering the cowl area, seal the entire length of the upper cowl grill to the cowl to W/S seal. Apply a thin bead of clear sealer to the slot in the seal where the cowl grille sits. This will seal the cowl grille to the cowl seal. F. Hard Top NOTE: LATER BUILT VEHICLES HAVE A MOLDED DRIP RAIL AROUND THE DOOR OPENING. THESE HARD TOPS CONTAIN SEVERAL IMPROVEMENTS OVER EARLIER TOPS, WHICH HAD EITHER STICK ON DRIP P RAILS OR NO DRIP RAILS AT ALL. IF PERSISTENT LEAKS OCCUR AROUND THE HARD TOP AND NORMAL SEALING AND ADJUSTMENTS DO NOT CURE THE LEAKS, REPLACEMENT OF THE OLDER TOP WITH THE LATER TOP WHICH INCLUDES THE MOLDED DRIP RAIL MAY BE REQUIRED.

7 Inspect the hard top to A pillar molding for the presence of a seal. (Figure 8). If no foam seal is present or any gap at this joint is present, replace the foam seal. This seal is part of the windshield molding on early built cars and is sold separately on later built cars in which it was fastened to the hard top. If replacement is required, hand cut a piece of foam 1/4 in. (6 mm) thick and trim it to fit this area. FIGURE 8 2. If leaks are present between the hard top and the body at the quarter panel area, remove the hard top and install foam tape to the hard top in this area. Trim the foam flush to the body after installation. 3. If leaks are present in the liftgate glass area, inspect the liftgate glass fit. The liftgate glass must be centered in the hard top opening. If the glass is not centered, loosen the mounting bolts and adjust the glass to center it in the opening. 4. Inspect the liftgate glass seal. Make sure that the ends are completely seated on the hard top flange. If leakage is still occurring at lower corner it may be necessary to seal the corners with clear RTV. Pull the seal away from the hard top and apply a small bead of RTV to the corner and install the seal. 5. If leaks occur at the top of the glass, replace the seal with p/n ** AF** or later. 6. If a leak is present inside the hard top at the rear upper corner, inspect the hard top for a small hole in the seam. Fill this hole with sealer.

8 G. Soft Top Door Rail leaks 1. Inspect the soft top door rails to A pillar molding for the presence of a foam seal. (Figure 8). If no seal is present, or there is any gap in this area, add foam to this area or replace this seal. Half Door Curtain Leaks 1. If leaks are present around the half door curtain perimeter seal, remove the door and inspect the lip on the seal. It must be higher than the edge of the curtain material binding. The seal should be parallel and have a consistent shape around the perimeter. If any problems are found with the seal, the door curtain must be replaced. 3. If the half door seal is rolled inside the vehicle when the door is closed, the windshield angle may need adjusting. Refer to the door section of this bulletin for windshield angle setting. H. Tailgate 1. If leaks are present in the tailgate area, adjust the striker to obtain a flush fit to the body. If leaks still persist, replace the liftgate seal with p/n AC. 2. If leaks occur at the lower corners, inspect the body for smooth sealer application, apply clear sealer to this area to smooth the joint if necessary. Policy: Information Only

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