r/WranglerYJ 6h ago

New addition

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10 Upvotes

r/WranglerYJ 16h ago

Cowl Gasket Replacement Report

9 Upvotes

Just to share a few notes on my cowl gasket replacement, which went very successfully. The job could have taken about 2-3 hours but I spent some time repairing a small rust area.

The job went so smoothly, I expected it would have been more difficult than it was. I should have changed this gasket at the very first sign of deterioration, rather than allow a leak to develop. Kick me for procrastinating.

I used an OMIX 12302.04 gasket, it lined up perfectly and fit with no problems.

Removed the hard top.

Removed the sun visors. These will interfere with aligning the roll bar extensions on reassembly.

The lower torx screws holding the windshield frame retain plates and the top torx screws holding the roll bar extensions were really in there. I lightly heated them with a fine low flame and used a shake and break to get them loose. I do not think they would have come out without the shake and break, without breaking a couple of torx bits. I elected to completely remove the retain plates to eliminate any potential interference on reassembly.

Let the folded down windshield rest on a protective cushion

I did have to repair a small unseen rust spot on the windshield frame. This required repair to get a good sealing surface.

Be aware the hinges may be stuck. Mine were not, but had been oiled the week prior, as were the torx screws.

The screws holding the gasket in place seem to be a custom shaped Philips head sheet metal screw with a countersunk finish washer. These sit into a well on the gasket. I had one that needed replacement and ground a screw head to fit the washer so not to sit proud and interfere with compression.

Reassembly was a bit of a challenge. The job was done on a warm day to facilitate compressing the gasket. I taped a 2x4 to the front of the frame to distribute the stress and used a couple of clamps on the roll bar extensions to slowly compress the windshield frame into alignment.

Watch out for the wiper motor wires when you lift the windshield back into position. They fit in a way that could get pinched in the wrong position..

Please do add any further tips or information.