Water Leaks

• This information applies to all Jeep models: 2/4 door & Hard/Soft Top. 
• 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.  .
• Each leak area can have multiple root causes, as noted in the diagnosis chart. It is important to water test each repair before starting the next. 
• 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. 
• 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  .
• If a leak cannot be reproduced, apply all the repairs as noted in the diagnosis chart. 
• 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 chart when determining which repairs to perform. 
• This repair procedure does NOT cover every possible water leak on the Jeep Wrangler. The issues identified in this document are the severe leaks that may occur in the field  .
• 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. 
• Generally, a car wash is the preferred method to diagnose a vehicle. 
• The content identifies the severe areas of water leaks, the critical characteristics of each area and how to repair them. 

Water Leak Conditions
Water is on door trim panel or Instrument Panel at A-pillar	Water is on center of Instrument Panel / Shifter	Water at Rear Hard Top Panel / B-pillar	Water is on front carpet
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• Repair Procedure for Windshield Header Seal 

This repair procedure is applicable when water is evident on the: 

• Door trim panel (1)
• Instrument panel / A-pillar (2)

1. Remove Header Seal (1).
   Fig 3: Butyl & Tape Residue

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   A rubber wheel bit may be used to aid in residue removal

2. Remove all butyl (1) and tape residue (2).
3. Clean surface with general adhesive cleaner.
4. Alcohol wipe entire surface and allow to dry.
   Fig 4: 4Mm Butyl

   Courtesy of CHRYSLER GROUP, LLC
   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

5. Install 4mm butyl (1) in a pattern, as shown in illustration.
   Fig 5: Center With Butyl

   Courtesy of CHRYSLER GROUP, LLC
6. Fill in the center with butyl (1) and make certain to fill in all holes, wrinkles and step offs to allow for a smooth surface to bond the tape / butyl to the new seal.
   NOTE:

   Excessive amount of butyl (1) can cause transition voids/leaks. Make sure to smooth out butyl (1)

   Fig 6: New Seal

   Courtesy of CHRYSLER GROUP, LLC
7. Locate and install the new seal.
8. Line seal up at end points (2) on both the left and right side of header.
   CAUTION:

   THIS STEP IS CRITICAL, if not done correctly leak will return

   NOTE:

   It is also critical to pressurize the area at the ends of the seals as indicated in corner areas (1)

   NOTE:

   A small roller or firm finger pressure should be used to be certain the tape is adhered completely from side to side

9. 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.

• Repair Procedure for Door Fit and Primary Seal 

This repair procedure is applicable when water is evident on the: 

• Door trim panel (1)
• Instrument panel / A-pillar (2)

1. 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. If door is within specs proceed to step   3 . 

   NOTE:

   When adjusting the door the seal must always be replaced

2. Adjust the door gap and flushness as described. Refer to ADJUSTMENTS  .
   Fig 9: Door Seal

   Courtesy of CHRYSLER GROUP, LLC
3. Inspect door seal (1) for folds and tears.
4. If the door was adjusted or flaws have been located in the seal, replace door seal (1).

• Repair Procedure for A-pillar Mucket and Foam 

This repair procedure is applicable when water is evident on the: 

• Door trim panel (1)

Header Mucket- 

1. Inspect the header seal mucket for the seal being rolled under (1) the freedom panel or side rail.
2. If the seal is folded under (1), remove the freedom panel or side rail and reinstall making sure not to distort the mucket.
   Fig 12: Good Header Mucket

   Courtesy of CHRYSLER GROUP, LLC

   The header seal mucket (1) installed correctly, will appear as this - 

A-pillar Foam 

1. Inspect the freedom panel or side rail for damaged / missing foam.
2. If the foam is damaged or missing (1), replace the foam using the foam kit available through Mopar Parts.
   Fig 14: Good Foam Seal

   Courtesy of CHRYSLER GROUP, LLC

   The foam seal installed correctly, will appear as this - 

   Fig 15: Foam

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   Right side panel shown in illustration, Left side typical

   NOTE:

   The foam installation is similar for the soft top rail

3. Install the foam (1) to the freedom panel as shown in illustration.

• Repair Procedures for Freedom Panel Seals 

These repair procedures are applicable when water is evident on the: 

• Instrument panel (Center)
• Console / Shifter

Right Hand Freedom Panel 

1. Remove seal (1) on right side panel.
   Fig 18: Tape Residue & Butyl Residue

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   A rubber wheel bit can be used to aid in the removal of tape and butyl residue

2. Remove tape residue (2) and butyl residue (1) from panel.
   Fig 19: Seal Surface

   Courtesy of CHRYSLER GROUP, LLC
3. Clean seal surface (1) with general purpose adhesive cleaner and allow to dry completely.
4. Wipe seal surface (1) with alcohol and allow to dry completely.
   Fig 20: Right Hand Freedom Panel & Covered Surface

   Courtesy of CHRYSLER GROUP, LLC
5. Place right hand freedom panel (1) upside down on a covered surface (2) to prevent scratching.
   Fig 21: 20 mm & 15 mm

   Courtesy of CHRYSLER GROUP, LLC

   1 = 20 mm

   2 = 15 mm

6. Apply 4 mm diameter butyl to Rear Notch, as shown in illustration.
   NOTE:

   Follow groove between panels and push butyl firmly in place

   Fig 22: 20 mm & 15 mm

   Courtesy of CHRYSLER GROUP, LLC

   1 = 20 mm

   2 = 15 mm

7. Apply 4 mm diameter Butyl to Front Notch, as shown in illustration.
   NOTE:

   Follow groove between panels and push butyl firmly in place

   Fig 23: Right Hand Freedom Panel & Covered Surface

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   Keep freedom panel upside down for the initial installation of the seal

   NOTE:

   Secure the end molds first, then finish with the middle of the seal

8. Remove tape liner from the new seal.
   Fig 24: Rear Mold

   Courtesy of CHRYSLER GROUP, LLC
9. Align REAR edge of NEW seal (1) to Right Freedom Panel Notch.
10. Compress butyl by installing seal in direction of arrows.
    NOTE:

    No gap between installed seal and outer edge of freedom panels

    Fig 25: New seal Right Freedom Panel Notch

    Courtesy of CHRYSLER GROUP, LLC
11. Align FRONT edge of New seal Right Freedom Panel Notch.
12. Compress butyl by installing seal in direction of arrows.
    NOTE:

    No gap between installed seal and outer edge of freedom panels

    Fig 26: Seal Installation

    Courtesy of CHRYSLER GROUP, LLC
13. Flip panel back over to complete the seal installation.
    NOTE:

    A small roller or firm finger pressure should be used to be certain the seal tape is adhered from front to rear, THIS STEP IS CRITICAL

14. Locate seal cross car against the middle rib in the freedom panel and pressurize starting at the ends and working toward the center.
    Fig 27: Show Locator Rib

    Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    This figure is for reference only. Panel is cross cut to show locator rib (1) in the panel

    Fig 28: Front of panel

    Courtesy of CHRYSLER GROUP, LLC
15. On the front  of the panel install GREY  30 X 75 mm Foam (1), from the Foam Kit. Locate the foam along trim lines of flame tip (2).
    NOTE:

    Make sure foam covers butyl completely

    Fig 29: Rear of panel

    Courtesy of CHRYSLER GROUP, LLC
16. On the rear  of the panel, install BLACK  30 X 75 mm foam (1), from the Foam Kit. Locate the foam along trim lines of flame tip (2).
    NOTE:

    Make sure foam covers butyl completely

LEFT HAND FREEDOM PANEL 

1. Place Left hand freedom panel (1) upside down on a covered surface to prevent scratching.
   NOTE:

   The following steps will be applied to the Rear corner (2) of the left side freedom panel (1)

   Fig 31: 70 mm & 25 mm

   Courtesy of CHRYSLER GROUP, LLC

   1 = 70 mm

   2 = 25 mm

2. Add 4mm diameter butyl, to rear inboard corner groove, as shown in illustration.
   NOTE:

   Push butyl firmly into groove between panels until FLUSH

   Fig 32: Black Foam

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   Make sure foam covers butyl completely

3. Add 30 X 75 mm Black Foam from the Foam Kit to cover butyl.

• Repair Procedures for Freedom Panel Latches 

1. If the vehicle build date is prior to 12/07/07, replace the front latches (2) with the superseded part as found in Mopar Parts.

• Repair Procedure for Hard Top Seal 

This repair procedure is applicable when water is evident on the:

• B-pillar roll bar
• B-pillar trim
• Freedom panel screw holes

1. Inspect for any inconsistency (3) or deformation between the seal (1) and hard top (2).
   Fig 36: Seal & Hard Top

   Courtesy of CHRYSLER GROUP, LLC
2. Inspect for any gaps between the seal (1) and hard top (2) edge.
   Fig 37: Bad Gap

   Courtesy of CHRYSLER GROUP, LLC
3. Inspect the end molds for poor installation.

   The end mold installed incorrectly, will appear as this- 

   Hard Top Seal (2) protrudes to far downward from the Hard Top (1) toward the B-pillar (3).

   Fig 38: Good Gap

   Courtesy of CHRYSLER GROUP, LLC

   The end mold installed correctly, will appear as this- 

   Hard Top Seal (2) located between Hard Top (1) to the B-pillar (3).

   Fig 39: Seal & Hard Top

   Courtesy of CHRYSLER GROUP, LLC
4. Inspect underneath the seal (1) for any skips with the tape / butyl along the entire Hard Top (2) mating surface.
   Fig 40: Seal

   Courtesy of CHRYSLER GROUP, LLC

   Example of tape skip. 

   NOTE:

   If there are multiple skips or the leak cannot be stopped, replace seal

   NOTE:

   A rubber wheel bit can be used to remove the tape

5. Remove all tape / butyl and clean with alcohol prior to replacement seal installation.
   Fig 41: Pre-apply Butyl & Hard Top

   Courtesy of CHRYSLER GROUP, LLC
6. Pre-apply butyl (2) in area shown on hard top (1), prior to installing the seal.
   Fig 42: 2 Mm Underflush

   Courtesy of CHRYSLER GROUP, LLC

   1 = 2 mm

   NOTE:

   It is critical that the end molds are installed correctly and sufficient pressure is applied to wet out the butyl / tape

7. Seal should be 2mm underflush (1) from the hard top edge to the seal edge. Measure and adjust as necessary.
8. Apply sufficient pressure to be certain butyl / tape has bonded thoroughly.

• Repair Procedure for B-pillar Mucket 

This repair procedure is applicable when water is evident on the: 

• B-pillar trim or seat

1. Inspect the mucket for a rolled under condition (1).
2. Inspect the mucket for a missing drain hole (2).
3. If either of these conditions exist, replace the mucket detail.
   Fig 45: Good Mucket

   Courtesy of CHRYSLER GROUP, LLC
4. Reinstall the panel or side rail making sure not to distort the mucket (1).

The header seal mucket (1) installed correctly, will appear as this - 

1. Inspect Freedom Panel for damaged or missing foam.
2. If the foam passes inspection skip to step #8.
3. If the foam is damaged or missing, replace the foam using the Foam Kit available through Mopar Parts.
   Fig 47: Foam & Panel

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   This foam (3) is in addition to the foam (2) that is already on the panel (1)

4. Add an additional piece of foam (3) to the freedom panel as shown in illustration This foam can be created by cutting the 30 x 75mm GREY foam in half, from the Foam Kit.
   • Repair Procedure for Rear Wheel Flare Hole 

   This repair procedure is applicable when water is evident on the: 

   Fig 48: Leak Path

   Courtesy of CHRYSLER GROUP, LLC
   • Front floor (wet carpet)
   • 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

   Fig 49: Origin Location

   Courtesy of CHRYSLER GROUP, LLC
   1. Remove Rear Flare. Refer to MOLDING, WHEEL OPENING, REMOVAL .

      Leak origin location (1) are the holes located under the Rear Flare.

      Fig 50: Holes

      Courtesy of CHRYSLER GROUP, LLC

      Hole (1) : 

      NOTE:

      Vehicles built prior to 5/28/08 will require this repair

   2. Inspect the body for missing or misaligned tape over the hole (1).
   3. Add/Replace a tape patch over the hole.

      Hole (2) : 

      NOTE:

      Vehicles built prior to 5/01/09 will require this repair

   4. Inspect the body for missing or misaligned tape over the hole (2).
   5. Add/Replace a tape patch over the hole.

      Hole (3) : 

      NOTE:

      Vehicles built prior to 7/22/08 will require this repair

      NOTE:

      To avoid appearance issues, be certain foam does not extend past the flare trim line

   6. Cut the BLACK 30 x 75 foam, from the foam kit, in half and apply over this hole.
   7. Reinstall wheel flare. Refer to MOLDING, WHEEL OPENING, INSTALLATION .
   • Repair Procedure for Cowl Side Panel 

   This repair procedure is applicable when water is evident on the: 

   Fig 51: Front Floor

   Courtesy of CHRYSLER GROUP, LLC
   • Front floor (wet carpet)
   Fig 52: Dash Panel, Front Floor & Cowl Side Panel

   Courtesy of CHRYSLER GROUP, LLC

   1 - DASH PANEL

   2 - FRONT FLOOR

   3 - COWL SIDE PANEL

   Location of the leak is the Cowl Side Panel (3).

   Fig 53: Cowl Panel Area

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   These leaks can be diagnosed by applying a water hose in the cowl panel area (1)

   Fig 54: Mastic Patches / Plugs & Seam Sealer Skips

   Courtesy of CHRYSLER GROUP, LLC

   Condition (1) : Mastic Patches / Plugs 

   1. Replace patch or plug.

      Condition 2: Seam sealer skips 

   2. Apply clear sealer to skip area.
      Fig 55: Strap Bracket, Scuff Trim Foam Damaged / Missing & Antenna Grommet Not Seated

      Courtesy of CHRYSLER GROUP, LLC

      Condition 3: Check strap bracket 

   3. Remove bracket and apply butyl to holes.

      Condition 4: Scuff trim foam damaged / missing 

   4. Replace trim clips.

   Condition 5: Antenna grommet not seated 

5. Re-install grommet.