FZJ80 Replacement Front Door Speaker Install

[OlyWaFJ]

I found some older information, a lot of broken photo links and a couple of WAY too detailed videos on how to replace the factory door speakers. I want my 80 to look good from 10 feet away not 10 inches and I don't want to spend a bunch of money or time figuring it all out. I'm not an audiophile but I don't like to listen to the buzz of a torn speaker. I also want them to be loud enough so I can hear people talking clearly while on the freeway when I'm using bluetooth calling. I went with the Pioneer TS-G1645R 6.5" speakers, inexpensive and I know folks have had success with them in the past. This is going to be photo heavy because I like to see details and not assume anything.

From start to finish it took me 75 minutes to complete the driver side door.

I'm not going to go through how to take the door panel off there are plenty of good threads already showing you how.

The factory speaker had some sort of seal sticking it to the door, used a trim tool to break it loose.

I cut the speaker wire right next to the solder so I would have plenty to work with for the new speakers, yes the wires are original but copper is copper and since they aren't cracked and still working I'm not going to bother replacing them right now, maybe later.

I used these screws from Home Depot that I picked up for $1.28

 

[OlyWaFJ]

Used a Sharpie Pen to color the heads black so you can't see them through the speaker grill.

Cleaned the speaker door frame with some rubbing alcohol

Bought a roll of this rubber seal from Home Depot (I think it was about $8.00) to provide the space needed for the speaker magnet so it doesn't hit the window, it should hold up pretty well.

Cut 4x pieces out and stuck them on between the nut holes.

 

[OlyWaFJ]

Popped these tabs of and removed the factory speaker grill

Used a razor blade to cut the panel hole large enough for the new speakers and bolts to fit flush. This is what takes most of the time go slow and steady so you don't slip and destroy your panel. I only cut out one section or about 2 inches at a time as you can see here

Should look like this when you are done, but don't put the razor blade away yet there is still more trimming to do.

Now you need to bend the tabs on the speaker up so they don't extend past the edge.

 

[OlyWaFJ]

I soldered the wiring pigtail to the new speaker.

Used a small socket wrench with a 3/8" socket to screw into the mounting holes of the speaker, the holes that lined up made "pioneer" writing angled to the front, no big deal to me not entering this into any car show competition. Used the top and bottom mounting holes to attach it to the door frame.

Here is a shot of the window clearance using this rubber molding method, shadow of the light makes it appear close but there is probably 3/8 of an inch clearance.

Time to start putting it back together but don't forget to feed the door controls wire through the panel now because the two other screws will also secure the panel to the door frame. I forgot on the passenger side and had to work to fish it through the hole while it was already screwed on.

 

[OlyWaFJ]

You need to cut out small notches for the screw head to allow the panel to sit flush, also a very small notch to allow the grill screws to easily fit into the speaker hole.

Here is the speaker grill frame mounted using the black screw heads even though the flash washed them out. I also used the Sharpie to color the brown panel backing black so it couldn't be seen through the speaker grill.

Finished speaker install..

Oh yea and I replaced the 1993 stock AM/FM/CD/Tape head with a JVC KD-X350BTS radio, also seen is my Icom 208H 2m/70cm Ham, Icom SAR mobile and Uniden CB.

 

[AchillesY]

Wonderful, Thank you for sharing.

 

[DSRTRDR]

you actually do not have to take the door panels off - I was able to do the replacement just by removing the speaker grilles

 

[sogncab]

I ordered 4 of these speakers today. The originals are roached. Hopefully they fit in the back as well. I'm guessing if they can be made to work in the front, the rear doors shouldn't be a problem.

 

[MTrun]

Random question - when installing these speakers and using the aftermarket harness to run 4 speakers (i.e. Metra 70-1761 wiring harness) are you guys still getting sound from the kick panel tweeters under the dash?

 

[CO2Enjoyer]

I ordered 4 of these speakers today. The originals are roached. Hopefully they fit in the back as well. I'm guessing if they can be made to work in the front, the rear doors shouldn't be a problem.

were you able to get them to fit in the rear?

 

[sogncab]

were you able to get them to fit in the rear?

Negative. I did a shallow mount Pioneer in the back. They weren't terribly expensive and they sound okay.

 

[CO2Enjoyer]

Negative. I did a shallow mount Pioneer in the back. They weren't terribly expensive and they sound okay.

Did you end up staying with 6.5 or going to 4 inch?

 

[sogncab]

Did you end up staying with 6.5 or going to 4 inch?

I'm sorry man, I misled you. These are the pioneer speakers I put in the back doors. They're tight, but they do work.

 

[CO2Enjoyer]

I'm sorry man, I misled you. These are the pioneer speakers I put in the back doors. They're tight, but they do work.

Sounds good thanks for your input I just got 4 of the 6.5 inch ones and im hoping they fit alright as well

 

[sogncab]

Sounds good thanks for your input I just got 4 of the 6.5 inch ones and im hoping they fit alright as well

I originally wanted to run a set of shallow mount Kicker in the rear, that's the one that didn't fit in back. I have 4 of them in my 40 and they sound decent.

 

[captainva]

I just installed Kicker 46CSC654 in my back doors and so far so good. These also fit in front doors fit with a 0.25" spacer and some 3d printed adapters but haven't gotten them buttoned up yet.

 

[450080LX]

Installed the pioneer TS-G650s in my front doors. Will be grabbing the hardware that OP used, but I was able to install the speaker without the marine rubber sealer. I used the grille spacer from the OEM speaker set up. It’s already closed up, but I will get photos when I do the other side. Got too excited to snap pics. Very minimal cutting of the door card, I just made windows for each screw.

 

[sparkybronco]

Thanks for posting this - just installed these speakers in my front doors. For what its worth, I actually found it easier to remove the door card. Used bolts that were same thread/diameter as the ones holding stock speakers in place, just longer. Like others, had to trim door card a bit.