Repair Procedure

1. Disconnect and isolate negative battery cables from shock tower.

2. Remove front bumper fascia as necessary to clear removal path of front fender and headlamp housing.

3. Remove rivets securing wheel well splash shield to fascia and sill/lower fender cladding.





4. Remove fender bolt to lower cowl. Loosen fender bolt to upper cowl (Figure 1).

5. Remove bolts attaching fender to radiator closure panel.

6. Support hood, remove lower hood prop mounting bolt.

7. Remove bolts to upper rail.

8. Remove outer most screw from the cowl screen.

9. Remove fender from vehicle.

10. Remove the door grommet boot from the retainer using a plastic trim stick.





11. Release the four latches of the retainer with a hooked probe (cotter pin tool). Pull the retainer/connector assembly out of the A-pillar (Figure 2).

12. Disconnect the two connectors in the retainer.

13. Inspect the terminals for any sign of corrosion or contamination. The white insulator may have a blue tint similar to the color of washer fluid (Figure 2). If corrosion is present proceed to step # 14. If no corrosion is present proceed to step # 19.

14. If an insulator shows signs of corrosion, all wires must be removed by clipping them at the base of the insulators using a wire cutter.

15. Strip the insulation from the wires to expose 1/8 in. of copper wire, make sure the strands of wire are not cut, just the insulation.

16. The body side harness connectors use female terminals and the door side harness connectors use male terminals.

17. Carefully crimp new terminals onto the wires using a crimping tool, Snap-On, # PWC47, or equivalent.

18. Assemble the repaired circuits into the new insulators. Transfer the circuits into the new insulators. Use the connector that was removed with the clipping procedure in step # 14 to see which wire goes into which cavity.

19. Grease all cavities of both connectors with Mopar Dielectric Grease, p/n J8126688.





20. Inspect the A-pillar/cowl load beam body seams (Figure 3). Remove any excess/squeezed out, over expanded, body sealer material from the seams. Clean area with Mopar Super Clean, p/n 04886330AA, or equivalent.

21. Seal all body seams with Mopar Paintable Repair Sealer, p/n 04318026, or Mopar Firm Setting Body Sealer, p/n 04856952, or equivalent.

22. Water test vehicle to make sure no water is entering the A-pillar/cowl area.

23. Install the repaired door wire harness insulators into the retainer.

24. Connect the door harness and body harness insulators.

25. Install the grommet boot into the retainer. The nipples on the inside of the boot must seat into the groove on the retainer or the grommet will not be properly seated and it will leak.

26. Insert the foam block, p/n 04759673AB, above the harness insulator inside the A-pillar/cowl to divert any water away from the connector.

27. Install the fully assembled body/door connection into the body until it clicks. The arrow on the grommet boot should be pointing up.

28. For fender installation, reverse the above procedures, steps 1 thru 9.

29. Repeat procedure on the other side of vehicle if necessary.