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Discussion Starter · #1 ·
I thought all doors for 97-06 were the same. I have half doors and a buddy of mine has full. I wanted to see how quiet they were so we decided to do a quick swap. I have a 97 Sport, he has a 99 Sahara. And...the swapped doors don't fit! They were off vertically by about 1/4 inch. Does one of us have "custom" aligned hinges (i.e. not standard due to an accident or something), or are they not all interchangeable among the TJ years? Or is it because his is a Sahara vs my sport? I thought Sport & Sahara were just trim/engine packages anyway. I sure thought they would be the same. We were both really surprised to find them not fit correctly. If I have to only find hard doors from a 97, it's really going to limit my search for hard doors. Any advice would be appreciated. I want hard doors for this winter.
 

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there shouldn't be any difference in the doors that I know of, all the doors you find are 97-06 for sale that I had found, and the half door's vs the full door should be on the same hinge point.
 

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I thought all doors for 97-06 were the same. I have half doors and a buddy of mine has full. I wanted to see how quiet they were so we decided to do a quick swap. I have a 97 Sport, he has a 99 Sahara. And...the swapped doors don't fit! They were off vertically by about 1/4 inch. Does one of us have "custom" aligned hinges (i.e. not standard due to an accident or something), or are they not all interchangeable among the TJ years? Or is it because his is a Sahara vs my sport? I thought Sport & Sahara were just trim/engine packages anyway. I sure thought they would be the same. We were both really surprised to find them not fit correctly. If I have to only find hard doors from a 97, it's really going to limit my search for hard doors. Any advice would be appreciated. I want hard doors for this winter.
the hinges are adjustable. hard or soft tops?
 

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Discussion Starter · #4 ·
the hinges are adjustable. hard or soft tops?
Oh really? Maybe that's the deal. How do you adjust? Spacer washers or something? We both have soft tops on now, but he also has a hard top. His door was high on mine, both vs the top opening, and vs the height of the latch.
 

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Oh really? Maybe that's the deal. How do you adjust? Spacer washers or something? We both have soft tops on now, but he also has a hard top. His door was high on mine, both vs the top opening, and vs the height of the latch.
the door hinge halfs that are mounted to the body have torx head bolts......loosen them and adjust
 

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the door hinge halfs that are mounted to the body have torx head bolts......loosen them and adjust
Loosen only the hinge bolts on the new doors to adjust them, otherwise your existing doors won't fit afterwards. Be careful loosening those torx-had bolts. They are soft and easily stripped out if you're not careful. Use only a fresh new high-quality torx bit adapter and use a 1/2" ratchet drive wrench to provide enough leverage so you can twist the bolts hard enough while keeping control over the torx head so it stays straight and fully seated into the bolt head. Better yet, don't use a 1/2" ratchet drive, use a longer "breaker bar" that provides greater power/leverage so you can more easily keep the torx head adapter under control and straight while you loosen the bolts.

The bolts are held in tight with Locktite so they are not easily unscrewed, which is why you have to be extra careful with those particular bolts or you'll find yourself stripping out their torx-shaped openings due to the softeness of the bolt head.
 

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I stripped mine out when I bought new hinges for my jeep. I ended up having to use an impact chisel to break them loose.
 

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X2 ^ on what Jerry said. As a matter of fact, you should never adjust the body side of any door hinge, on any vehicle.:D
 

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i had to weld hex nuts to the torx bolts to get them out. broke two off had to take door panel off put vice grips on the end of the bolt sticking out to remove them. used anti-seeze, not lock tite when i put it back togather.
 
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