NUMBER:
GROUP:
DATE:

23-010-13
Body
February 27, 2013

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, or otherwise, without written permission of Chrysler Group LLC.

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-001-12 REV. A, DATED MAY
30, 2012, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CORRECTION TO THE
APPLICABILITY STATEMENT.
SUBJECT:
Water Dripping Across Door Sill And/Or Damp Front Floor
OVERVIEW:
This bulletin involves diagnosing potential leak paths associated with water dripping across
the door sill and/or damp front floor. If necessary, procedures for notching the passenger
and/or driver side door seals, inspecting along the bottom edge of the door seal channel
for possible sealer skips, antenna grommet inspection and passenger side weather strip
stuffer repairs are covered.
MODELS:
2011 - 2012

(JK)

Wrangler

2011 - 2012

(J3)

Wrangler (Export)

NOTE: **This bulletin applies to vehicles built prior to March 15, 2012 (MDH
0315XX).**
PARTS REQUIRED:
Qty.

Part No.

Description

1 (AR)

55397484AB

A Pillar Foam, RH

1 (AR)

55397485AB

A Pillar Foam, LH

1 (AR)

68153263AA

Stuffer

1

68027813AA

Butyl Tape

1

04467709

Mopar Bond All Gel (.06oz)

NOTE: One .06oz. tube of Bond All will service 9 vehicles and One roll of Butyl Tape
will service 6 vehicles.
SPECIAL TOOLS/EQUIPMENT REQUIRED:

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-2-

NPN

Diagonal Cutters

NPN

Trim Clip Remover

NPN

Isopropyl Alcohol

NPN

3M 4298 Adhesion Promoter or Equivalent

NPN

Shop Water Supply/Hose for Leak Testing

NPN

P10200 Kent Hi-Tech Clear Seam Sealer (5oz)

NOTE: One 5-once tube of seam sealer will service 4 doors.
SYMPTOM/CONDITION:
The customer may experience water dripping across the door sill and/or a damp front floor.

Fig. 1 Water Leak Path
1 - Front Door Sill (Waterleak)
2 - Front Floor
3 - Door Panel Front Lower Fastener

DIAGNOSIS:
NOTE: When the door is open, if there is water run off from the roof, it can soak the
carpet. Be sure to explain to the customer that this condition cannot be
repaired. This is an unfortunate condition with this type of vehicle, similar to
convertibles.
1. Water leak test the entire vehicle primarily along the top of the door seal and down the
A-pillar area for leaks.
NOTE: Hose test should be a minimum of 5 minutes or until the water leak point is
found.

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23-010-13

2. Did water enter the vehicle by dripping across the door sill?
a. Yes >>> Proceed to Step #1 of the Repair Procedure.
b. No >>> Proceed to the next step.
3. Was water and or dampness present on the front floor?
a. Yes >>> Proceed to Step #13 of the Repair Procedure.
b. No >>> Further diagnosis required, this bulletin does not apply.
REPAIR PROCEDURE:
1. Open the door on the side with leak present and mark the door seal (1) approximately
below the lower door panel fastener (2) or the area where water is running across the
sill(Fig. 2).
2. Remove the lower section of the door seal (1) from the door seal channel below the
arrows indicated on either side of (1) in (Fig. 2).

Fig. 2 Door Seal Modification Location
1 - Door Seal
2 - Door Panel Lower Fastener (Notch Location)
3 - Door Panel

NOTE: Be careful when notching the door seal so that the inside wall of the bulb
seal (3) is not cut when the notch (1) is cut into the outer “wet side” (2) of the
door seal. (Fig. 3) shows the desired result of the door seal notch procedure
outlined in Step #3 with relation to the structure of the seal and the layout of
the notch on the seal relative to the door.

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Fig. 3 Seal Modification Desired Result
1 - Seal Notch (Area to be Removed)
2 - Outer Door Side of Seal (“Wet Side”)
3 - Inner Door Side of Seal/Bulb (“Dry/Body Side”)

3. Locate the mark (1) made in Step #1 on the door seal, below the lower door panel
fastener, and designate it as the center of the notch (3) which should be approximately
5/8”/(16mm) wide (4) (Fig. 4).
4. Using diagonal cutters, (2) cut approximately 1/4”(6mm) into the outer door/”wet side”
of the seal on either side of the seal center mark (1) outlined in top pictures 1 & 2 of
(Fig. 4).
5. Connect the two cuts from Step #4 by cutting along the bottom side/door bulb side of
the seal as outlined in picture 3 of (Fig. 4)
6. Connect the two cuts from Step #4 by cutting along the top side/door channel “flat
side” of the seal as outlined in picture 4 of (Fig. 4)
NOTE: Use caution not to cut into the bulb seal portion of the seal while performing
the notch procedure.

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23-010-13

Fig. 4 Seal Modification
1 - Door Seal Notch Mark (Center of Notch)
2 - Diagonal Cutters
3 - Door Seal Notch
4 - Door Seal
5 - Seal Notch Width (5/8”/16mm)

7. Inspect the sealer (5) applied along the inboard lower edge of the door seal channel
(3).
8. Were any sealer skips present?
a. Yes >>> Proceed to Step #9.
b. No >>> Proceed to Step #10.
9. Seal any skips (4) where there may be a void between the door seal channel (3) and
the bottom of the door (1) with Kent Hi-Tech clear seam sealer.
NOTE: Follow the manufacturer's recommendations for surface preparation and
curing times.

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-6-

Fig. 5 Sealer Skip Inspection
1 - Door (Bottom Side)
2 - Door Seal (Bottom of Door)
3 - Door Seal Channel
4 - Seam Sealer Skip
5 - Seam Sealer (Correctly Applied)

10. Reinstall the lower section of the door seal (1) back into the lower door seal channel
so that the door seal notch (2) faces outward toward the “wet side” of the vehicle.

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23-010-13

Fig. 6 Reinstall Door Seal
1 - Door Seal
2 - Door Seal Notch
3 - Door Panel
4 - Door Panel Lower Fastener (Notch Location)

Water leak test the entire vehicle primarily along the top of the door seal and down the
A-pillar area for leaks.
NOTE: Hose test should be a minimum of 5 minutes or until water leak point is
found.
11. Was water still entering the vehicle onto the front floor?
a. Yes >>> Proceed to the next step.
b. No >>> Return the vehicle to the customer.
12. Was water dripping down the cowl-side inner body panel under the Instrument panel
or dripping down the front of the door seal from the A-pillar area?
a. Cowl-side inner body panel >>> Proceed to Step #13.
b. Door Seal from A-pillar area >>> Proceed to Step #16.
13. Remove the passenger side front speaker. Refer to the detailed procedures available
in DealerConnect>TechCONNECT> under: Service Info> 08-Electrical> SPEAKER>
Removal> Instrument Panel - Passenger Side
14. Through the glove box opening (3) with the passenger side speaker and glove box
removed verify that the antenna grommet (1) is properly seated to the inner body side
(Fig. 7).

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-8-

NOTE: The antenna grommet is a pull to seat type of grommet. If the grommet is not
pulled through the cowl-side inner body panel enough to be properly seated,
it must be pulled gently toward the vehicle interior in order to seat it. If the
grommet has been over-pulled through the cowl-side inner panel, push it
outboard and seat it properly. Make sure that the main wire harness (2) is not
pushing on the antenna grommet causing it to be pushed out of the inner
body side panel.

Fig. 7 Antenna Grommet Inspection
1 - Antenna Grommet
2 - Main Wire Harness
3 - Glove Box Opening View (Glove Box removed)

15. Was water also dripping down the front of the door seal from the A-pillar area?
a. Yes >>> Proceed to Step #16.
b. No >>> Proceed to Step #30.
16. Open the suspect front door and disconnect the door wiring harness (1) by pushing
red lock and remove cloth check strap (2) from hook (3) (Fig. 8).

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23-010-13

Fig. 8 Disconnect Door Harness and Check Strap
1 - Check Strap Harness
2 - Check Strap
3 - Check Strap Hook

NOTE: Use a foam block or equivalent to prevent the sideview mirror from hitting
the vehicle when the door is full open (Fig. 9).

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-10-

Fig. 9 Prevent Door Contact
1 - Foam
2 - Potential Damage Area
3 - Door

17. Remove the suspect door upper weatherstrip seal (1) at the A pillar upper corner, from
metal channel (2) enough to gain access to stuffer access slot (Fig. 10).
NOTE: Inspect the side upper door seal channel (2) for possible sealer skips
18. Were any sealer skips present?
a. Yes >>> Proceed to Step #19.
b. No >>> Proceed to Step #20.
19. Seal any skips where there may be a void between the door seal channel and the top
of the door with Kent Hi-Tech clear seam sealer.
NOTE: Follow the manufacturer's recommendations for surface preparation and
curing times.

-11-

23-010-13

Fig. 10 Door Weatherstrip Removal
1 - Door Weatherstrip
2 - Metal Weatherstrip Channel

20. Pull out half of the existing stuffer that goes down the front A-pillar side of the door
weatherstrip through the access slot in the backside of the weatherstrip (Fig. 11).

Fig. 11 Door Stuffer Access
1 - Door Stuffer
2 - Door Weatherstrip

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-12-

21. Remove half the existing stuffer (1) by cutting at the stuffer relief joint using scissors
(Fig. 12).

Fig. 12 Door Stuffer Removal
1 - Stuffer
2 - Scissors
3 - Door Weatherstrip

22. Insert the new stuffer (1) into the weather strip where existing was removed (Fig. 13).

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23-010-13

Fig. 13 Install New Door Stuffer
1 - New Stuffer
2 - Weatherstrip

NOTE: For ease of installation lubricate the stuffer with soapy water.
23. Clean stuffer sections to be bonded with isopropyl alcohol and allow it to flash.
24. Bond both stuffers at the intersection (1) with Mopar Bond All Gel (2) and make sure
there is no gap between stuffers as shown in (Fig. 14).
NOTE: The glue is being used to keep the new a-pillar stuffer in position and to
prevent it from moving down the weatherstrip over time.

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-14-

Fig. 14 Door Stuffer Installation
1 - Stuffers
2 - Mopar Bond All Gel
3 - Weatherstrip

25. Remove existing foam patch (1) and clean door surface with isopropyl alcohol (Fig.
15).

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23-010-13

Fig. 15 Foam Removal
1 - Foam Patch (right side shown)
2 - Weatherstrip Retaining Clips
3 - Weatherstrip

26. Wipe door surface with adhesion promoter and once flashed insert the new foam
patch (Fig. 16).
NOTE: Ensure foam patch is tight against upper door weatherstrip channel by
beginning installation at the top of foam and finishing at the bottom. Make
sure foam gasket is applied flat against the door with no creases or wrinkles.

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-16-

Fig. 16 Foam Installation
1 - Edge of Door Weatherstrip Channel
2 - Foam (right side shown)
3 - Upper Door Seal Channel

27. Install approximately 1 inch of butyl tape to upper door weatherstrip channel as shown
(Fig. 17).
NOTE: Press butyl down with fingers to seal against the sides and bottom of the
channel and along edge of foam.

-17-

23-010-13

Fig. 17 Butyl Tape Installation
1 - Butyl Tape
2 - Door Seal Channel
3 - Foam Patch (right side shown)

28. Reinstall the door weatherstrip seal.
29. Reconnect the cloth check strap and door wiring harness as shown in (Fig. 8)
30. Water leak test the vehicle primarily along the top of the door seal and down the
A-pillar area for leaks.
NOTE: Hose test should be a minimum of 5 minutes or until water leak point is
found.
31. Did water continue to saturate the front floor?
a. Yes >>> Further diagnosis required.
b. No >>> Return the vehicle to the customer.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation
No:

Description

Amount

23-51-09-91

Front Door Weatherstrip, Repair and Apply
Sealant to Skip - One Side (1 - Semi-Skilled)

0.2 Hrs.

23-51-09-92

Front Door Weatherstrip, Repair and Apply
Sealant to Skip - Both Sides (1 - Semi-Skilled)

0.3 Hrs.

08-60-05-91

Antenna Grommet, Inspect and Seat (1 Semi-Skilled)

0.2 Hrs.

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23-51-10-92

Weatherstrip, Install Stuffer and Foam Patch One Front Door - Right Front Door (1 Semi-Skilled)

0.4 Hrs.

23-51-10-95

Weatherstrip, Install Stuffer and Foam Patch Both Front Doors (1 - Semi-Skilled)

0.6 Hrs.

FAILURE CODE:
ZZ

Service Action