JEEP CHEROKEE 1995 Service Repair Manual

(4) Remove the key lock cylinder retainer clip. Re-
move the lock cylinder, gasket and clip from the door
opening (Fig. 16).
(5) If applicable, remove the door latch-to-lock cyl-
inder rod from the original lock cylinder. Connect it
to the replacement lock cylinder.
INSTALLATION
(1) Position the lock cylinder and gasket in the
door opening. Hold the lock cylinder in the opening
with the retainer clip.
(2) Connect the door latch-to-lock cylinder rod to
the door latch.
(3) If equipped, connect the security alarm switch
connector to the lock cylinder.
(4) Test and, if necessary, adjust the door latch-to-
lock cylinder rod operation.
(5) Install the door trim panel and waterdam.
(6) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR LATCH ADJUSTMENTÐXJ
(1) Remove the access hole plug from the latch face
(Fig. 17).
(2) Insert a 5/32-inch wrench through the hole and
into the latch release lever adjustment screw and
loosen.
(3) Press and release the outside door handle latch
release button several times.
(4) Release the button and tighten adjustment
screw to 3 Nzm (30 in-lbs) torque.
(5) Test the release handle button and key lock cyl-
inder for proper latch release.
(6) Install the door waterdam and trim panel.
DOOR EXTERNAL HANDLEÐXJ
REMOVAL
(1) Remove the door trim panel and waterdam.
(2) Remove the access hole cover and remove the
door handle nuts (Fig. 18).
(3) Disconnect the handle-to-latch rod from the
handle latch release lever arm.
(4) Remove the nuts and handle from the door.
(5) Remove the gaskets from the door outer panel
surface, if necessary.
INSTALLATION
(1) Assemble the replacement door handle, if nec-
essary (Fig. 19). Apply silicone spray lubricant to the
components.
Fig. 16 Key Lock Cylinder Removal/Installation
Fig. 17 Door Latch Adjustment
Fig. 18 Door External Handle Removal/Installation
23 - 48 DOORSÐXJJ

(2) If the original gaskets were removed, position
the replacement gaskets on the handle. Position the
handle on the door outer panel.
(3) Install and tighten the handle nuts.
(4) Connect the latch-to-handle rod to the handle
latch release lever arm.
(5) Install the door waterdam and trim panel.
(6) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR LATCHÐXJ
REMOVAL
(1) Remove the access plug located at the upper
end of the door (Fig. 20).
(2) Remove the door trim panel and waterdam.
(3) Remove the door external handle from the door
outer panel.(4) Remove the door latch screws (Fig. 21).
(5) Remove the retainer clip and key lock cylinder
from the door outer panel.
(6) Disconnect all the rods from the door latch (Fig.
22).
Fig. 19 Door Handle Components
Fig. 20 Access Plug
Fig. 21 Door Latch Retaining Screws
Fig. 22 Door Latches
JDOORSÐXJ 23 - 49

(7) Remove the door latch from the door face.
(8) For vehicles equipped with power door locks,
remove the lock motor rivets. Remove the motor and
latch as a unit from the door. Detach the rod and mo-
tor from the latch (Fig. 23).
INSTALLATION
(1) If necessary, install a replacement latch striker
(Fig. 24).
(2) For vehicles equipped with power door locks,
attach the rod and lock motor to the latch. Attach the
lock motor to the door panel with either rivets or
with bolts and nuts (Fig. 23).
(3) Install the door latch at the door face and con-
nect all the rods to the latch.
(4) Install the latch screws. Tighten the screws to
9Nzm (77 in-lbs) torque.
(5) Install the external handle.
(6) Install the latch-to-door handle rod.
(7) Install the key lock cylinder and retainer clip.
(8) Install the door waterdam and trim panel.
(9) Install the door access plug.(10) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR INSIDE LATCH RELEASE AND LOCK
RODSÐXJ
REMOVAL
(1) Remove the door inside latch release handle
screws (Fig. 1 and 2).
Fig. 23 Door Lock Motor
Fig. 24 Door Latch Striker Removal/Installation
Fig. 1 Front Door Inside Latch Release Handle
Fig. 2 Rear Door Inside Latch Release Handle
23 - 50 DOORSÐXJJ

(2) Move the door release handle outward and dis-
connect the handle-to-latch rods (Fig. 3). For vehicles
equipped with power door locks/windows, also discon-
nect the wire harness connector (Fig. 4).
(4) Drill-out the rivet heads and remove the rod
guide bracket rivets from the door inner panel (Fig. 5
and 6).
(5) Remove the rod guide brackets and rods from
the door.
INSTALLATION
(1) Position the rod guide brackets and rods in the
door.
(2) Install rod the guide bracket rivets in the door
inner panel (Fig. 7).
(3) Install the door trim panel and waterdam.
(4) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
Fig. 3 Door Inside Latch Release Rods
Fig. 4 Power Switch Wire Harness Connector 16
(3) Remove the door trim panel and waterdam.
Fig. 5 Front Door Rod Guide Bracket and Rods
Fig. 6 Rear Door Rod Guide Bracket and Rods
Fig. 7 Rod Guide Bracket Installation
JDOORSÐXJ 23 - 51

DOOR HINGE/HINGE PIN REPLACEMENTÐXJ
REMOVAL
(1) Remove the door restraint (check) retaining pin
(Fig. 8) with a punch.
(2) Front door: open the door wide for access and
remove the door hinge pin and bushing with a punch.
(3) Rear door: with the door closed, remove the
door hinge pin and bushing with a punch (Fig. 9).
(4) Remove the door hinge bolts, plates and shims
(Fig. 10).
(5) Retain the door hinge plates and shims for cor-
rect installation.
(6) Separate the hinge halves.
INSTALLATION
(1) Position the hinge plates, shims and replace-
ment hinge-half on the door face.
(2) Align the door hinges, plates and shims with
bolt holes and install hinge bolts (Fig. 10).
(3) Insert a bushing in both body hinge halves
from the bottom (Fig. 11).
(4) Allow the bushing material to stick out of the
top of the hinge. Use the round end of a ball-peen
hammer, lightly tap the bushing material to begin to
roll it outward (Fig. 12).
(5) When the entire edge of the bushing is rolled
outward, turn the hammer over and lightly tap the
bushing material to form a flat head (Fig. 13). The
head must be flat without overlapping or distorting
the bushing material.
(6) Slide the door half of the upper and lower
hinges onto the body half of both hinges and align
the hinge pin holes.
(7) Carefully start the hinge pins through the
hinges (they will fit snugly) and then use a two
pound hammer, carefully seat both hinge pins (Fig.
Fig. 8 Door Restraint (Check) Retaining Pin
Fig. 9 Rear Door Hinge
Fig. 10 Door Hinges, Bolts, Plates and Shims
23 - 52 DOORSÐXJJ

14). Be careful not to bend the hinge when driving
the hinge pin, support may be required under the
hinge.
(8) Adjust/align latch striker and latch as neces-
sary.(9) Install the door restraint (check) retaining pin
with a punch.
FRONT DOOR SPACER BLOCKSÐTWO-DOOR
VEHICLES
REMOVAL
(1) Upper spacer block: drill-out the rivet heads
and remove them from the reinforcement plate (Fig.
1).
(2) Lower spacer block: remove the screws from the
door face (Fig. 2).
(3) As applicable, remove the spacer block from the
door window frame or door face.
INSTALLATION
(1) As applicable, position the spacer block on the
door window frame or door face.
(2) Upper spacer block: Install the replacement riv-
ets in the spacer block and reinforcement plate.
Fig 11 Install Bushing In Hinge
Fig. 12 Begin To Roll Bushing Material Outward
Fig. 13 Forming A Head On The Bushing
Fig. 14 Installing The Hinge Pin
Fig. 1 Front Door Upper Spacer BlockÐTwo-Door
Vehicles
JDOORSÐXJ 23 - 53

(3) Lower spacer block: install the screws in the
door face. Tighten the screws to 1 Nzm (11 in-lbs)
torque.
DOOR EDGE GUARD/EDGE PROTECTOR
STRIPÐXJ
REPLACEMENT
(1) Pull outward and remove the door edge guard
strip from the door edge (Fig. 3).
(2) Position the door edge guard strip on the door
edge.
(3) Force the door edge guard strip inward until it
is seated on the door edge.
DOOR WINDOW EXTERIOR MOLDINGSÐXJ
REMOVAL
(1) When removing the front or rear door window
exterior molding, open the window completely (Fig. 4
and 5).
(2) Pry and pull the molding sections from the door
panel flange and clips.
Fig. 3 Door Edge Guard/Protector Strip
Fig. 4 Front Door Window Exterior Molding
Fig. 2 Front Door Lower Spacer BlockÐTwo-Door
Vehicles
23 - 54 DOORSÐXJJ

INSTALLATION
(1) When installing window moldings, start at the
forward end of the upper molding.
(2) Force the molding onto the door panel and con-
tinue rearward until it is completely seated on the
flange.
(3) Mate the rear molding with the upper molding
and force the molding edge inward.
(4) Continue pressing and moving downward to
complete the installation.
(5) Position the lower molding on the clips and
force it downward.
DOOR WINDOW GLASS AND DOOR OPENING
WEATHERSTRIP SEALSÐXJ
REMOVAL
When removing the front or rear door window glass
weatherstrip seals, open the window.
The window weatherstrip seals (Fig. 6 and 7) can
be removed by hand or with the aid of a small putty
knife (or similar tool).
Fig. 6 Front Door Window Glass Weatherstrip Seals
Fig. 5 Rear Door Window Exterior Molding
Fig. 7 Rear Door Window Glass Weatherstrip Seals
JDOORSÐXJ 23 - 55

The door opening weatherstrip seal is attached to
the periphery of the door opening in the body. The re-
taining push-studs can be removed with an appropri-
ate pry tool. The front door secondary seal is
attached to the A-pillar with plastic blind rivets (Fig.
8).
The door-to-rocker panel seals are attached to the
door inner panels with rivets (Fig. 9). The rivets can
be removed with an appropriate pry tool.WINDOW GLASS WEATHERSTRIP SEAL
INSTALLATION
When installing front or rear door window glass
weatherstrip seals, open the window completely.
(1) To install a front door window glass channel
weatherstrip seal, start at the upper, rear corner
(Fig. 10).
(2) To install a rear door window glass channel
weatherstrip seal, start at the upper, front corner
(Fig. 11).
(3) A small amount of adhesive can be used to hold
the weatherstrip seal in-place, if necessary.
(4) As applicable, move forward or rearward and
downward evenly until the weatherstrip seal is fully
seated in the channel.
Fig. 8 Door Opening Weatherstrip Seals
Fig. 9 Door-To-Rocker Panel Seals
Fig. 10 Front Door Window Glass Channel
Weatherstrip Seal
Fig. 11 Rear Door Window Glass Channel
Weatherstrip Seal
23 - 56 DOORSÐXJJ

(5) Position the belt weatherstrip seals at the win-
dow edge (Fig. 12, 13 and 14) and force them down-
ward until seated on the flange.
DOOR OPENING WEATHERSTRIP SEAL
INSTALLATION
The weatherstrip seal is attached to the flange
around the perimeter of the door opening with adhe-
sive and plastic push-studs.
(1) When installing a door opening weatherstrip
seal, start at the door sill center line.
(2) Use adhesive along with the push-studs to aid
in retaining a weatherstrip seal.
(3) Move upward and around the perimeter of the
door opening and seat the weatherstrip seal on
flange (Fig. 15).
(4) Install the front door secondary seal with plas-
tic blind rivets.
DOOR-TO-ROCKER PANEL SEAL
INSTALLATION
(1) Position the seal on the door inner panel with
the holes aligned.(2) Attach the seal to the door inner panel with
truss rivets.
Fig. 12 Front Door Belt Outer Weatherstrip Seal
Fig. 13 Front Door Belt Inner Weatherstrip Seal
Fig. 14 Rear Door Belt Outer and Inner Weatherstrip
Seal
Fig. 15 Door Opening Weatherstrip Seals
JDOORSÐXJ 23 - 57