the graphic insert and backing plate are in position and have not slipped down. If this occurs,
the lens will bind at the top and could break the top tabs.
H. Open door and turn lens release handles to the locked position.
5.2
DOOR DISASSEMBLY
5.2.1
DOOR REMOVAL
A. Open door. Turn key switch to OFF position and disconnect the harness at the top of the
door.
B. Gently push upward on the door to relieve the door’s weight from the gas spring and slide
the pin out of the clevis that anchors the gas spring to the door. Rotate the gas spring
down and out of your way.
C. While supporting the door with one hand, lift the hinge pin tabs up out of the retaining slots
and slide the tabs toward the center of the door.
D. Remove the door.
5.2.2
DOOR BOARD REPLACEMENT
A. Turn key switch to OFF position.
B. Remove the lens (see Section 5.1).
C. Remove the four (4) screws on the back side of the door, that secure the liner to the door
shell, and lift the front door shell enough to disconnect the door board to light board
harness. The door shell can now be removed.
D. Remove the screws that secure the spiders onto the door board. Remove the door board
by lifting the back end up first, so it slips out of the front tabs holding it down.
E. Replace the door board and secure the spiders back on.
F.
While supporting the bottom of the door shell with one hand, reconnect the door board to
the light board harness. This is best accomplished with the door closed and the top of the
door shell angled away from the unit
G. Secure door shell to the door liner with the four (4) screws
5.2.3.
ELECTRONIC LIGHT BOARD REPLACEMENT
A. Turn key switch to OFF position.
B. Remove the lens (see Section 5.1) and door shell (see Section 5.2.2.A).
C. Remove the two (2) screws securing the light board to the inner door assembly.
D. Remove light board by unplugging the door board to light board harness.
E. Replace board and secure with screws.
F.
Reconnect the light holder harness and secure the light holder/reflector assembly to the
door liner with the four screws.
G. Replace the door shell and secure with four (4) screws.
H. Replace lens assembly (see Section 5.1).
5.2.4.
DOOR LOCK SOLENOID
A. Open door and remove the four screws that secure the solenoid mounting bracket to the
interior surface of the door liner.
B. Gently slide the bracket out of the door liner and unplug the connector.
C. Loosen the large nut the secures the solenoid coil to the bracket and slide the solenoid
assembly out of the slot in the bracket. Orient the bracket with the hatch turned up to
prevent the plunger from falling out once it clears the bracket.
D. Replace the solenoid assembly and secure with the large nut. Check to ensure the
plunger lead-in angle faces the back side of the bracket, that the plunger moves freely,
and does not bind. Adjust the position of the coil, if necessary.
E. Connect harness and slide door latch assembly into slots in back of door liner. Secure
with mounting screws.
5.2.5.
DOOR SEAL REPLACEMENT
A. Grasp lip of door seal and gently pull the seal from the retaining slot in the back of the
door liner.
B. Lubricate the new seal with soapy water and insert of the retaining section of the seal
(starting first at each corner) into the slot in the door liner.
11
Summary of Contents for 85-3322
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