Door Waist Seal Replacement

These instructions will help you to remove the old window top seals and reinstall them with and without having to remove the glass (depending on method used). 

Parts needed per door:

• 1 outer door waist seal 
• 7 outer seal securing clips 
• 1 inner door waist seal 
• 7 inner seal securing clips 

Gain access to the inside of the door:

• Remove door pull if your TR is equipped with one.
• Remove door opening lever and window winder handle from inside the door - gently push and lever the plastic disk aagainst the spring. Insert something to hold it back. I used an allen wrench on each side (5/32 and 3/16"). Take a punch and tap out the retaining pin. Put the pins in a safe place so you don't loose them.
• Remove the screws at either end of the door pocket.
• Carefully remove the door trim panel.
• At the bottom of the door you will see a bracket held to the door with two little screws. Removing the screws will allow the window to be wound down a little further permitting easier seal installation.

Remove the window seals:

• Lower the window.
• Use a flat-tip screwdriver with a good square edge, place against the edge of each clip and gently tap screwdriver with a hammer until the clip pops off.
• When all the clips for the seal are removed, you should be able to pull it up and out.
• Repeat for the other seal.

Installing the window seals:

• If you have the padded door top and wish to replace it, do so now as the inner waist seal is installed over the fabric of the padded top.
• Buy or fabricate a clip installation tool.  One can be fabricated from a computer expansion card slot cover by bending the top tab into a hook that will cradle the clip.  You may want to put a small piece of double-sided tape in the hook to help hold the clip while installing.
• Place the inner seal (also known as the 'fuzzy seal') into place (it may have to be trimmed to fit properly).
• Place a clip into your tool and line it up with the first molded recess in the seal.
• Using one hand to hold the seal in the correct position, pull up until the clip is fully seated.
• Repeat to install the other six clips for the inner seal.
• Place the outer seal into position (it may also have to be trimmed).  Some people have reported having trouble with the window track interfering with placing/installing the rear-most clip, you may want to save it for last.
• Use the same method to install the clips as you did with the inner seal.

Alternate (Do it all at once) Method:

• Strip door down (remove window trim, window channels and regulator (see directions below), door pad).
• Install padded door top.
• Install inner door seal.
• Install front window track.
• Install window regulator.
• Install rear most clip of outer seal, along with outer seal. (The remaining clips were installed later)
• Install rear window track.
• Install glass (assembled with its bonded lower track).
• Install remaining clips of outer seal. These can be installed by clipping them on by hand while strategically positioning the window.

Finishing up:

• Clean out the bottom of the door as necessary. 
• Treat rust inside the door as necessary. Make sure front and read drains are clear.
• Reinstall door trim panel.
• Reinstall door opening lever and window winder handle.  TIP:  If you lost the pins to hold the handles in place, you can use 1/16" cotter pins or you can use an old wire coat hanger, straighten it out and notch it at the appropriate length to fit your handle - push the handle into place, insert the notched end of the coat hanger and bend to break at the notch.
• Reinstall door pull if your TR is equipped with one.

Window Channel Replacement

These instructions will allow you to remove the old window channels, replace the channel itself, and reinstall them without having to remove the glass or window trim. 

Please read the instructions before you begin. You should have several pieces of plastic inside the door. It is important that you leave them in place, or replace them if missing. These are to keep moisture from reaching the back of your interior door panels, so that they don't warp/rot. 

Parts needed per door:

• 2 window channels 
• 12 3/32" medium length rivets 

Gain access to the inside of the door:

• Remove door pull if your TR is equipped with one.
• Remove door opening lever and window winder handle from inside the door - gently push and lever the plastic disk aagainst the spring. Insert something to hold it back. I used an allen wrench on each side (5/32 and 3/16"). Take a punch and tap out the retaining pin. Put the pins in a safe place so you don't loose them.
• Remove the screws at either end of the door pocket.
• Carefully remove the door trim panel.

Remove the window channels:

• Raise the window.
• Remove the six bolts holding the front and rear window channels.
• Pull the rear channel forward and unhook the "anti-spread bar."
• While holding the window with one hand, remove the front channel with the other through the large opening in the bottom of the door.
• Lower the window about 2" then remove the three bolts in the center of the door supporting the winder mechanism.
• Lift the rear of the window and withdraw the rear window channel.
• Replace the three winder bolts so the window stays supported.
• Take a break and wash any grease off your hands.

Prepare brackets to be refurbished:

• Verify replacement channels match. Note one end is narrower. This is the top end. Cut the bottom end to length now. If the sticker is still wrapped around the channel, label them Front and Rear with an up arrow indicating the top.
• Label the brackets F, R, and 1, 2, and 3 (top, middle, and bottom) and with an arrow pointing up.
• I recommend having only one channel apart at a time to avoid mixing parts.
• Use a screwdriver to remove any remaining file and rubber inside the channel to expose the back of the rivets.
• Carefully drill out the old rivets on one channel. I recommend not drilling all the way through the rivet to avoid damaging the brackets.
• The brackets can then be snapped off and remaining rivet sections can be carefully removed.
• If the plastic/nylon guides from the top bracket are worn, you can tighten them by gently squeezing it in a vise.
• Use the old channel and brackets as a template and drill 3/32" holes in the new channel to match the old.
• Treat any rust on the brackets and paint the cut end of the window channel to protect it.
• Use a brad point drill bit (3/16") to clean from inside the channel of the rivet holes.
• Rivet brackets on to the new channels with 3/32" pop rivets. For the lower bracket, you can use a short spacer (like a larger heavy duty rivet) and rivet from inside the channel. For the upper bracket, you have to go from the back of the channel.
• Use a punch to flatten the ends of the rivets inside the channel as necessary.

Put things back together:

• Remove the three bolts in the winder mechanism.
• Insert rear channel.
• Insert front channel and attach anti-spread bar.
• Loosely install the bolts in the winder mechanism and window channels.
• Once everything is in place, tighten the bolts and verify the window goes up and down.

Finishing up:

• Clean out the bottom of the door as necessary. 
• Treat rust inside the door as necessary. Make sure front and read drains are clear.
• Reinstall door trim panel.
• Reinstall door opening lever and window winder handle.  TIP:  If you lost the pins to hold the handles in place, you can use 1/16" cotter pins or you can use an old wire coat hanger, straighten it out and notch it at the appropriate length to fit your handle - push the handle into place, insert the notched end of the coat hanger and bend to break at the notch.
• Reinstall door pull if your TR is equipped with one.

Fuzzy Door Seal Replacement

These instructions will allow you to remove and replace the door seals. 

Parts needed per door:

• 1 fuzzy door seal (Modern style w/attached rubber seal) OR
• 1 fuzzy door trim  AND
• 1 rubber door seal (Original format for TR4 and TR4A) (must have separate channel pieces to mount door seal)

Steps:

• Remove old door seal (and trim if two separate pieces) from around opening.
• If you have the two piece trim/seal setup and wish to convert to the more modern style, you will need to remove the door seal channel running around the door opening.  These are spot-welded into place - you can either use a spot-weld cutter (recommended) or you can chisel them out.
• If you chiseled them out, you will probably have small holes or extra bits of metal where the spot welds were - fill/grind as necessary to smooth metal out.
• Remove/repair any rust exposed, then paint/touchup as necessary.
• If you have the two piece trim/seal setup and did not wish to convert, now use some lubricant and coat the part of the door seal that fits inside the channel.  Starting at the top of the windshield, slowly tuck the seal into the channel, taking care not to stretch or kink the seal as you work you way around the door.  I try to compress the seal along it's length slightly to compensate for any possible shrinkage as it ages.  Once you have the seal inserted and are happy with it, trim away any excess.
• Again, starting at the top of the windshield, force the trim piece (old) or trim seal (new) onto the lip.  Work you way slowly around the door opening, making sure to seat it fully onto the body - especially in the bends.  Once it's in place, trim any excess.