I finally broke down and bought a new battery for the Scout this weekend after the donor battery from the Jeep decided it couldn’t crank the engine over anymore. While I was dealing with that (crank engine, jump out, twist the terminals down, jump back in, crank engine, repeat, repeat), the driver’s door latch spun itself around 180 degrees so that the latch would just prang off the striker uselessly. So, I tore the driver’s door down again and got inside to see what was happening with the mechanism.
A little backstory: In order to get the latch body out, the window needs to come out, and then the guide track closest to the handle. One bolt on my track was pretty well frozen but a little PBBlaster made short work of the other three. Once I had the track pulled away from the edge, the latch came free, and I compared it with another one I had in my spares (it’s the one on the right). Somehow the cam had gotten completely turned around and jammed itself into place. It had been “repaired” at some point in order to fasten the main pivot arm into place with a flattened bolt and nut, and the clip holding the door release rod was long gone—so they replaced it with a locknut hastily threaded onto the end of the rod. Instead of wasting time trying to fix the original, I shot the spare up with plenty of white lithium and used that instead.
While the driver’s door bolts were soaking, I tore the passenger door down and pulled the original regulator in there out. It looks to be a replacement unit like the ones sold by LightLine dealers (some of the original paint is still evident under the rust). I dropped the new one in, greased it up, buttoned the door back up, and then remembered that I need to tighten the outer door handle. D’oh! Eventually the window will need to come out and be replaced, because there’s some serious rust happening at the bottom of the channel on the inboard side, but that’s why I’ve got spares.
I also finished fabricating a strap stay for the bikini top out of a cut-down decking bracket and bolted that into place, as well as replaced six of the original grade 5 bolts holding the rollbar down with grade 8 hardware. I still have to drill four holes for bolts at the feet of the rollbar, which were never installed (there are only two on each side).
Finally, I’m going to order a ThermoQuad rebuild kit today. Wish me luck!