B. Door Latch Reinforcement Plate Replacement
NOTE:Only front passenger doors with screw heads that are not within the clearance holes and/or an inoperative secondary latch, as determined by the inspection in Section A, require reinforcement plate replacement.
NOTE:
The door window must be in the full up position before performing this repair procedure.
1. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.
2. Open the right front door and remove the interior door trim panel.
3. Remove the right front door speaker.
4. Carefully remove the door water shield.
5. Remove the lock knob rod from the door latch assembly.
6. Remove the two door glass run retaining bolts (Figure 2).
7. Using a plastic tie strap, temporarily tie strap the glass run forward to gain access to the latch assembly.
8. Remove the three latch retaining screws (Figure 2).
9. Disconnect the outside door handle to door latch rod and remove the latch assembly.
10. Disconnect the door latch rod from the outside door handle.
11. Using a center punch, carefully center punch each of the 10 spot welds that hold the door latch reinforcement plate to the door frame (Figure 3).
12. Using a spot weld drill bit (Snap-on YA2550-2 or equivalent) or a sharp twist drill bit, drill out the spot welds that hold the reinforcement plate to the door frame (Figure 4).
13. Remove and discard the original latch reinforcement plate.
14. Remove any burs in the spot weld holes on the door frame.
15. Using a small grinding wheel, clean all paint and primer from around each spot weld hole on the door frame.
CAUTION:
Failure to clean the weld area around the holes may cause difficulties during the welding process.
16. Place the latch reinforcement plate into position and mark the location of each spot weld location.
17. Remove the reinforcement plate from the door. Using a small grinding wheel grind the areas marked so that the protective coating is removed from the latch reinforcement plate.
18. Using locking pliers, clamp the new latch reinforcement plate into position on the door frame (Figure 5).
NOTE:
The latch reinforcement plate must be tight against the door frame before welding.
19. Using a MIG welder, weld the holes closed (Figure 6). Refer to the "Welding Specifications" chart at the end of this procedure for welder setup specifications.
CAUTION:
Allow the panel to cool after each hole is welded to prevent the metal from warping.
20. Using a small grinding wheel, grind the welds flat.e welds flat.
21. Using rust resistant primer, flood the inside of the door area around the latch reinforcement plate with primer. Apply a heavy enough coat so that the primer runs between the reinforcement and the door frame.
22. Paint the area of the door frame using methods approved by DaimlerChrysler and the paint manufacturer.
NOTE:
Both the inside and outside of the door frame and latch reinforcement plate must be painted before reassembling the door.
23. Install the door latch rod onto the outside door handle.
24. Place the door latch assembly into position and connect the outside door handle rod to door latch assembly.
25. Install the three screws that hold the door latch to the latch reinforcement plate
26. Remove and discard the tie strap that held the glass run forward to gain access to the door latch assembly.
27. Install the two bolts that hold the door glass run in position (Figure 2). Tighten the bolts to 80 in. lbs (9 N.m).
28. Install the lock knob rod from the door latch assembly.
29. Carefully install the door water shield.
30. Install the right front door speaker.
31. Install the interior door panel.
32. Connect the negative battery cable.
33. Verify door operation and adjust door striker if required.