Remove D2 back door interior panel HOW?

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Author Message   John Friederich Posted on Saturday, November 09, 2002 - 06:27 pm:    Can you give advice on removing the inside panel & pull for a 2001 rear door? I need to drill new holes & trim sheet metal of the spare tire carrier to accomodate new larger spare (now matching the rest!) I can actually close the door, but only with the tire aired down to 15 psi, and it still rubs on the bumper. The wife doesn't like it, so needs to change. Thanks for your help... -John F.   Carter Simcoe (Carter) Posted on Saturday, November 09, 2002 - 06:32 pm:    Should be the same as a DI right??? If so just take apart the subwoofer assemply, undo the screw in the inside door handle and pry the thing of with a big screwdriver.   Paul D. Morgan (V22guy) Posted on Sunday, November 10, 2002 - 07:24 am:    Good Morning John, If you do not have a panel removing tool from a body shop; just take a #4 Standard Screwdriver and wrap a couple layers of duct tape around the sharp end. Then take your "special tool" and slowly pry between the door and the flimsy panel. WARNING: you will probably break 80% of the plastic tabs that hold it on place. Once you have the entire circumference broke free, remove the phillips head screw that connects the inside door handle. The door panel should come out. Check out http://expeditionexchange.com/disco2tires/ Paul '00 Pig   John Friederich Posted on Sunday, November 10, 2002 - 10:16 am:    Paul - Thanks, don't know how I missed that link... I assume I can pick up clips I'll likely break from the dealer. Since my tires are 255x70 MT/R, I only require 1/4 inch extra - instead of inverting, I am going to try just elongating the carrier holes downward with a drill, then pushing it up as I assemble to get the extra clearance. Even 1/8" will keep the tire from rubbing the bumper, so I think I can get away without inverting. Again, thanks. John F   Paul D. Morgan (V22guy) Posted on Sunday, November 10, 2002 - 11:51 am:    Hey John, IMHO, I would go ahead and invert because you just might go bigger in the future. The DII Wheel wells are huge and can house a lot of "meat". Plus, the principle of elongating holes is not a mechanically sound one. The red clips are easily obtainable from the dealer. Paul '00 Pig   Jerry Crawford (Jcrawford) Posted on Sunday, November 10, 2002 - 06:32 pm:    Those clips are really expensive too. You can save a lot of them using a simple trim tool from NAPA or PEP like the one on my tech web page here- abut half way down the page (Laying the coax wire). I had to remove and refit the trim pannel a number of times so I got pretty good at it. BTW, WATCH OUT for those damn little aluminum screws used to hold the speaker mesh covering face in place. The Phillips heads will strip out very easy - and - you have to return the short one back into the hole it came out of or you punch a hole in your speaker!   John Friederich Posted on Sunday, November 10, 2002 - 08:39 pm:    I wound up breaking 5 of 21 of the red clips. I elongated the holes - I know this is not mechanically sound, but was easy, and gave me 1/4" clearance over the bumper. I'll let you all know if it creeps down - I suspect it won't though. If I go larger rubber in the future, then I'll have to invert, I guess. John F   Dean Brown (Deanbrown3d) Posted on Monday, November 11, 2002 - 01:32 am:    John, IMHO lever the panel off with a flat screwdriver, and who cares if you break a few (I did). Invert the tire carrier plate, and drill the extra 2 holes. When you put the new tires on, the windscreen wiper will be in the way. But undo the top nut, pop off the arm, rotate it by a few degrees clockwise, and put it back. Its like a steering wheel cog, with multiple positions. Dean   Jerry Crawford (Jcrawford) Posted on Monday, November 11, 2002 - 06:41 am:    Dean, the problem with not caring if you bust a few of the plastic pins is you peobably will also bust out the shape of the door trim pannel slots as well with that heavy handed approach. You only have a charboard/preessboard shape inthere under the leather and once you bust out the slots that hold the pins your screwed as far as goo fit goes.   Dean Brown (Deanbrown3d) Posted on Tuesday, November 12, 2002 - 12:42 pm:    Jerry - I have the SD model, all plasticy and no leather around there, and evidently its much more robust.