Removable XJ doors done easy (and cheap)

Old 05-25-2011, 03:46 AM
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Join Date: Jan 2011
Location: Big Lake, Alaska
Posts: 181
Year: 1996
Model: Cherokee
Engine: 2.5
Default Removable XJ doors done easy (and cheap)

Removable doors done easy:

Tools needed:
Angle grinder w/ cut-off wheel and abrasive wheel
Torx driver for door bolts
Hammer
Vise grips
10mm deep socket
Felt tip marker

First disconnect any wires leading from in cab to the door, removal of door panel will be needed. With the needle nose vise grips pull the pin for the door catch located between the upper and lower hinges. Next remove the 6 bolts holding the door to the hinges, I used PB Blaster and loosened all the bolts before fully removing all of them. I also removed the lower bolts before the uppers.

Remove the door catch from within the door, the hinges have travel limitation of their own.

Next clamp the hinges in the open position with the vise grips, cut the bottom of the hinge as shown in my pictures. *Note* the drivers side pins were driven down so the lower end fell off after cutting, passenger side was opposite.

After cutting the lower portion of the hinges off, remove them from the vehicle. Using the 10mm socket and a hard surface drive the pin from the cut piece from the passenger side and drive it back into the upper portion of the cut hinge.

Replace the hinges back into place, mark the pins as shown in the pictures. Use the cut off wheel to cut the pins, grind a rounded point on the cut end of the pin.

The backing plate that sits behind the hinges needs to be trimmed too, trimming can be seen in the pictures, I cut 1.25" off at a 45 degree angle.

Once everything has been cut and ground to your desired finish, reinstall the hinges on the door, do not tighten bolts all the way. Lift doors into place, this may take some effort to align the loose hinges the first time. Once the door is set in place make adjustments to hinges to set door in correct position, tighten center bolt snugly and carefully remove doors. Tighten all bolts and reinstall doors, make sure that it all works after tightening (may take a few tries).

I used a soundbar to eliminate my speakers from my doors, I'm sure a suitable connector can be found at an electrical supply for all power connections, mine in all manual. Also eliminate the dome light switches by removing them or simply removing the bulb while not using doors.
Attached Thumbnails Removable XJ doors done easy (and cheap)-image-106947547.jpg   Removable XJ doors done easy (and cheap)-image-2887771334.jpg   Removable XJ doors done easy (and cheap)-image-2510340945.jpg   Removable XJ doors done easy (and cheap)-image-2001499219.jpg   Removable XJ doors done easy (and cheap)-image-1442009345.jpg  

Removable XJ doors done easy (and cheap)-image-3639405384.jpg  
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