Overall Water Leaks Diagnosis And Testing

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1. Check if top is latched at header and secure fully:
   1. From inside the vehicle, pull the handle (1) on the header latch downward to engage the hook into its receiver (2). Repeat on the other side.
   2. Pull the handle (1) back upward while squeezing the hook, locking the latch into place.

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2. Check that the soft top is positioned in the door rail trough (3) correctly (1) and not hanging over the side (2).

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3. Check 3 and 4 bow paddles, adjust and repair or replace as necessary
4. If the vehicle is equipped with plastic bow paddles (1) they should be replaced with updated metal paddles.
   1. Remove the rivet (2) and release the fabric.
   2. Pull the paddle (1) out of the fabric pocket (3) and remove from the bow.
   3. Install the new metal paddle (1) into the bow.
   4. Position the new paddle into the fabric pocket (3) and weave the tension cable through the fingers of the new paddle.

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5. Check if Velcro from top cover to quarter window is attached

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6. Check if quarter window canards (2) are attached at rear door rail (1) and to j rail

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7. Check if D-pillar stiffener (2) is secured to top cover (1). and tailgate retainer clips

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8. Check if D-pillar stiffener (1) is secured to the tailgate retainer clips (2).

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9. Check for gap between top cover and quarter window.

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10. Make sure the quarter window is tucked up behind the spring retainer as shown in the illustration.

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11. Check if rear window is secured to top cover, quarter window (2), and j-rail (1).
12. Check for spring attachment and orientation

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1. Check if the A-pillar mucket (1) push pin fasteners (2) are fully engaged to door rail

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2. Check if foam (1) is attached to front door rail trough and even with the ridge (2).

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3. Check that the front door rail foam (1) is present and undamaged.
4. Check the B-pillar mucket seal (3) is installed correctly with no gap at the B-pillar (2) and seated fully up against the door rails.

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5. With the top folded back check and replace the foam seal on the header bow.

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6. Slide the new foam (1) up under the fabric (2) and seat fully.

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1. Rubber extrusion seal damaged or installed incorrectly (if equipped)

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2. C-pillar J-rail Mucket Leak, replace if necessary.

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3. Remove the bolts (4), lower the brackets (1) and remove the door rail assembly (2).
4. Check the foam seal (3) is present and not damaged, replace if needed.
5. Replace the mucket seal and install the door rail (2).

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6. Rear Door Frame Mucket Leak

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7. Check if threads are showing from 2 vertical fasteners at rear door rail joint

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8. If threads are not showing, check for movement between upper and lower door rail and tighten the screws securely.

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9. Check if foam is installed at joint shown in illustration (requires removing 3 fasteners from door rail) repair or replace as necessary.

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10. Remove the three J-rail retaining screws (1).

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11. Remove the J-rail (1) from the door rail (2) and install new foam on the bottom before installing back.

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1. If equipped, check if foam is present at bottom of rear window stiffener and replace if needed.

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Windshield Header Foam/Butyl Replacement (change to spear foam)

• Replaces usage of L-Foam, Butyl Chicklet, and Razer foam
• Improves manufacturability, water sealing, and wind noise capabilities
• 4 mm Ebony ESL 600 material
• Butyl backing (adhesive)
• LH and RH mirrored parts

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1. Using a small punch (2) or equivalent, remove the seal rivets (1) and lift the end of the seal out of the way.

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2. Remove L shaped foam (1), butyl patch (2) and lower razor foam (3) and clean all surfaces fully prior to installation of the new spear foam.

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3. Begin installation by placing the spear foam (2) onto the windshield frame.
   1. Start at the tip of the foam (1).
   2. Place tip into radius of windshield frame (1) as shown in illustration.
   3. Foam corner (3) sits parallel with windshield header bathtub (4).

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4. Seat the remaining foam around the header of the windshield frame maintaining a tight even gap to the forward edge of the frame (1).
5. Make sure foam is fully seated to windshield frame along the radius to avoid pocketing under the foam (2) that can allow water to pass.

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6. Make sure header seal (1) is positioned evenly side to side (2).

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7. Make sure header seal is fully seated in the windshield frame and foam (1) is not visible between frame and seal. If visible, pull end of header seal forward.

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8. Install the new rivets (2).
   NOTE:

   A slight bit of the spear foam should protrude from the lower feathered edge of the seal (1) when properly installed.

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1. Check windshield frame panel seam sealer (1) using shop air and soap test. Using a paintable repair sealer Part No. 04318026AB or equivalent, repair as needed.

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2. Check windshield urethane (1) for voids or gaps using soap and air.

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3. Check drain tube (1) for damage and make sure boot (2) is secured to drain trough properly.

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4. Check drain trough for sealer skips or voids with water bottle test.

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5. Inspect the trough end cap for sealer voids, cracks or damage.