Hard top to header issues

[CJK440]

I have an 03 with an early vented top. I noticed my hard top leaked between it and the header last winter while the soft top did not. I started the swap today and noticed the soft top door surrounds have a soft foam piece that surrounds the pilot wedge that mates into the plastic under the header seal. The hard top had some old crusty foam residue that sat in a stepped area which is now removed. I outlined the stepped area that had foam.

For the life of me I cant find any info on foam pieces for the TJ hard top other than the top-to-tub camper seal. Is there supposed to be foam on the front of the hard top? Is it available or just make your own?

 

[macleanflood]

That doesn't look right...did someone hack up your hard top?

Zoom out a little more.

-Mac

 

[CJK440]

This view may make a little more sense. I assume the header rubber will contact the top north of that horizontal step, but below it and around the alignment block is about 1/8" recessed. I didn't mount the top to check but assume there will be a gap between the top and that plastic track the alignment block fits into. This makes for a gap in the surface where the door seal touches which is right where the water comes in.

Its a factory early top, with a pentastar on the back glass.

Without any further info I'll make up some L shaped adhesive foam pads to close that gap but TJ's aren't a rare vehicle, if there is supposed to be foam pads here I would imagine I would have found something on the net about them, replacement foam, youtube video, forum posts but all I see is just JK foam. Are they called something else?

Header seal

 

[chili_pepper]

For the life of me I cant find any info on foam pieces for the TJ hard top other than the top-to-tub camper seal. Is there supposed to be foam on the front of the hard top? Is it available or just make your own?

Yes, there are supposed to be shaped foam pieces at that location on both sides, without them you will likely experience a severe water leak (ask me how I know ). As far as I know, no one supplies them with the hardtop seal kits or as a separate item. Not even sure if Mopar lists them as a purchasable part. I am in the process of rehabbing my LJ's hardtop and removed what was left of mine. I created a CAD drawing of the profile of the foam piece, figured I'll be cutting my own to replace them.

Yours may be a different shape.

 

[CJK440]

Yes, there are supposed to be shaped foam pieces at that location on both sides, without them you will likely experience a severe water leak (ask me how I know ). As far as I know, no one supplies them with the hardtop seal kits or as a separate item. Not even sure if Mopar lists them as a purchasable part. I am in the process of rehabbing my LJ's hardtop and removed what was left of mine. I created a CAD drawing of the profile of the foam piece, figured I'll be cutting my own to replace them.

Yours may be a different shape.

Thanks for confirming I am not crazy. I have some foam from the center of a pickup 3rd brake light that should work good. I will employ CAD also (Cardboard assisted design).

So strange that these aren't reproduced.

Looks like what you sketched looks different than what I would need. I assume an LJ hard top would have a front section like a later non vented TJ top. Perhaps there lies the difference between my early top.

 

[chili_pepper]

Thanks for confirming I am not crazy. I have some foam from the center of a pickup 3rd brake light that should work good. I will employ CAD also (Cardboard assisted design).

So strange that these aren't reproduced.

Looks like what you sketched looks different than what I would need. I assume an LJ hard top would have a front section like a later non vented TJ top. Perhaps there lies the difference between my early top.

My passenger side was missing completely, leaving an approx. 1/4" gap between the top and header not covered by the door seal. When it rained, the water literally pissed through the gap and directly into the footwell below. Thankfully Jeep tubs have drain plugs.

 

[txbemis69]

i’ve replaced the cowl, header and both door seals with oem mopar seals a still have a substantial leak on the passenger side where the front edge of hard door meets windshield frame and hardtop. have never had these foam pieces since i got the jeep nor have i ever seen them in a parts diagram. maybe this is the missing piece of the puzzle. smdh!

 

[chili_pepper]

a substantial leak on the passenger side where the front edge of hard door meets windshield frame and hardtop.

I know exactly what you mean. If you are missing these on your hardtop, they will make a difference. If you plan on making them, it's okay if the foam is a bit on the thick side.

But even with the foam, I still suffer from this. Can't seem to find a decent replacement door seal anywhere. On #3 now in 12 months, they all seem to be a bit shite.

 

[txbemis69]

I know exactly what you mean. If you are missing these on your hardtop, they will make a difference. If you plan on making them, it's okay if the foam is a bit on the thick side.

But even with the foam, I still suffer from this. Can't seem to find a decent replacement door seal anywhere. On #3 now in 12 months, they all seem to be a bit shite.

oem hard door seals were hard to find and the windshield header seal was on back order for over six months. mopar parts website kept telling me to not cancel my order that they were being made by the manufacturer. almost gave up on it. i’d like to see detailed pictures of your foam pieces before and after install. that would give me something to go on.