Friday, January 30, 2015

How to remove door internals

I've done this a couple of times before but anyhow it was challenging to recall the correct order of disassembling the doors so this time I decided to to document the process for future. The main order in the disassemble is to work from front to rear so that the vent window comes out first and the locking system comes out last. So here is how I did it.

1. Remove the window crank, door latch crank and the door handle
2. Peel the door upholstery panel out and remove the cardboard behind it
3. Unscrew the window crank limiters.
The upper of them is the up limit and the lower is supposed to limit the low position
4. Remove the C-clip and the roller from the scissor channel in the and unbolt the 2 nuts 
5. Loosen  the 4 bolts from the window crank mechanism and the 3 bolts
which hold the scissor entity to the inner door panel
6. Lift the window upward so that you can 
7. Remove the 2 c-clips and rollers which hold the scissor to the channel in window
The scissor system can now be pulled off the window frame
8. While holding the window up , use your other hand to remove
the 7 bolts that hold the scissor and crank mechanism.
Now the mechanism is loose and may be dropped to the bottom
of the door and pulled out.  If it does not drop at this point see phase 12 and return here and continue
9. Loosen and remove the two bolts from the vent window
10. Loosen and remove the two nuts which secure the adjustable
screws of the vent window
11. If possible screw in the adjustable screws of the vent window.
They cannot be removed until the vent window is lifted upwards a couple of inches
(my lower adjustable screws was so tight with rust that it could not be removed even then)
12. If not possible in phase 8 you can now lift and move the vent window so that the
window mechanism drops to the bottom and can be removed.
13. Remove the bolt and window up limiter from the front of the bottom frame of the window
14. Lower the window to the bottom of the door
15. I will replace my furry belt line weatherstrip so I removed them at this point.
16. The vent window can now be lifted about 2 inches so that
you can remove the adjusting bolts out of the openings in the window.
Once done lift the vent window out of the door. 
17. Move the window forward and start working at the rear of the door
Remove the 4 screws that hold the gasket on the upper opening 
Remove the 2 cups covering the openings
Remove the 2 bolts and 1 nut holding the rear window run
Remove the short bolt holding the window rear limiter but do not remove the hex head screw
18. By moving the window forward and up inside the door you can now remove the rear run
19. Lift the window up and move it rearward and slide it out

 
I was unable to remove the vent window adjusting screw so I did not manage to pull it out. Therefore I did have to define an application to the above instructions so that I did not remove the vent window but lifted it up as much as possible and hung it so that it remained out of the way until the rear run was removed. 

Once both doors were done, they we sent to soda/sand blasting. The passenger side door may have chances to be recovered but the driver door will need some patching and a new door skin panel.





This interior panel had the date Sep. 28 1964 stamp on it.

Panorama view of the door shell


Window crank limiters

Limiter openings

Scissor channel, clips and rollers

Front scissor channel in the bottom of the window frame 

Rear scissor channel in the bottom of the window frame

Window crank scissor system removed

Loosening the vent window securing bolts




Vent windows lifted for removal of the adjusting nuts

Home made hoist to be able to loosen the rusted adjusting bolts.
The rear run is being pulled out.

Vent window removed
Hi Jackers sticker is so '70s








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