JGRP548WP02 Whirlpool - Instructions

The exact part for this oven is no longer available. I purchased one hat was close in size, but larger than the original. Upper and lower brackets hold the glass in place, so length was not a problem but height was. I removed the upper brackets, re-shaped them with the vise, a hammer and metal shears. The glass would now sit inside the bracket where the screws also went. I had to be quite careful the screws did not shatter the new glass.

The hardest part was aligning the 4 holes for the top brackets. Since 2 holes were on one piece of the door, and 2 were on the other (holding the glass sandwiched between) precision was critical. Also the screw length was critical because the glass now sat in a area where it could come in contact with the screws. (I know - pictures would be most helpful, and I didn't take any.)

Using tape and lots of patience, I got the holes aligned. I covered the old holes inside the oven door with spare screws. I filed down the points of the sheet metal screws so that, if they contacted the glass, they would not be pointed.

Once everything was reassembled, I turned the oven on high for about 1/2 hour to ensure the heated metal and glass all played nicely together. We've had no problems in the month since the repair.

Removed the 6 screws securing the door and inner frame unit. Lifted off the frame and inner glass unit. Then, after cleaning all the broken glass, put the new glass in; first reattaching the inner frame and then the outer door cover.

The other comments from folks who had done this were very helpful!
I had to go look up the directions for removing the door. To do this flip the latches on the hinges and then close the door as far as you can and pull up, it will come out.
Now lay the door flat on the kitchen counter and take out the 6 screws you can see on the edges and inside of the door. They are all the same so you don't have to keep them organized. Now you can take off the outer door with the handle (lift the inner door out since you will have the door face down at this point) and get it out if the way. Remove the hinges and set them aside but don't get them mixed up.
Next, take out the screws on the inner glass rails, there are two rails. Keep those rails in order for replacement. Take out the middle glass and clean it (this took oven cleaner and a razor blade on the one I had).
Take the middle of the door apart and expose the soft gasket (don't move it!). Clean out any broken glass and Insert your new glass. Put the middle piece of the door back on and line up all the screw holes! Put the first of the glass rails back on and the cleaned middle glass back in place, then the second glass rail. Put in the two screws that hold the glass rails.
Now you are ready to put the door back together. USE THE BOX TO HOLD THE DOOR OFF THE COUNTER WHILE YOU PUT THE HINGES BACK IN AND PUT THE DOOR FRONT BACK ON! If the screw holes don't all line up start the screws and work your way around, you'll get them to go in.
Voila! Door fixed.

Since the problem would only occur when the right front burner was on, I first replaced the ignitor, but the problem persisted. To replace the spark module I had to pull the range out of the nook it is in in the counter top. Then (after ensuring that the power was off) I removed the back cover. The spark module was easily located and removing two screws and disconnecting a few wires liberated it. The new one went in easily since it is the same part number and an exact match. Put the back on and check that the problem was solved. Done!

Pull the end of the lens nearest the oven door out of the oven wall. Because our oven is several years old and the bulbs had not been previously changed, I could not pull the lens out with my hand, so used two small screwdriver under the metal tabs which hold the lens in place, the metal holder came out with the lens. Once the lens is removed, simply pull out the old bulb and, either while wearing surgical gloves or holding the bulb with a cloth (do NOT allow bare skin to touch the bulb or you will be replacing it again sooner rather than later), push the new bulb's pins into the socket. The lens then is simply pushed back into place.

I am not the handiest guy around so i was a little nervous doing this job but figured i would take a crack at it ( no pun intended). Took the door off as per instructions from kitchenaid , unscrewed all the outer screws , took off the back of door unscrewed the metal bar holding the glass in ( there are 3 levels of glass) took the 2 good glass sheets out got to the broken glass removed that put the new one in , replaced all the other glass and screws and put door back on, and i felt so proud. Probably saved about 150 dollars by doing it myself. I feel so proud.

Removed the small access cover on the bottom of the cooktop by reaching inside and under the cabinets. Removed the module which was held by two hex head screws, unplugged the wires noting the location and color of the wires. Plugged the wires into the new module in the proper locations as noted previously. Attached the module with two screws, and then attached the cover/access plate with two screws. Problem resolved, repair was easy.

This was more difficult than anticipated - probably because I'd never done it before. Once I got the door off (I didn't have the proper pins and used nails but didn't realize they had to be headless) I found all the screws, which were relatively easy to take out. I was surprised that the thermal door glass was obscured by two other panes of glass. It took more disassembly than anticipated and a few false starts when reassembling, but all in all it got done. I was happy that a job that would have cost probably $300 or more ended up getting done for $40 plus my labor - which isn't worth much these days. I'd certaily do it again.

Installed new spark module by removing back panel of stove. Removed two screws holding old module. Disconnect lines, marking colors. Installed new. Problem not solved. Out $128 since new module was not returnable after install.
Called Judd and Black service department. Tech came on service call. Said it was bad gas valve. They ordered part. Than needed two weeks to install. I installed it and problem persisted. Could not return part because I installed it myself. Out $180. I had cleaned ignitor with alcohol from top. Took apart cooktop and cleaned from bottom. Problem fixed for free. Out over $500 in parts and labor.

Read all the way through this once before doing it. It really helps in keeping pieces and parts separated. First I had to take off the oven door. Please do this as it will make your life so much easier! The owners instructions does a lousy job explaining how to do this. You need to insert a small Allen wrench into the holes behind the door hinge pin. Just stick them in there and leave them. If you don't have Allen wrenches you can use small nails or the like, but you have to put something into the holes. Close the door slowly, yes it will feel like you are going to break the hinges or the wrenches. When you get the door almost completely closed you should wiggle the door a bit by the handle and pull up. The door will come off. Once you get the door off you can get to work. Leave these wrenches in the hinge holes. You will need a flat surface big enough to lay the door down to work on it. Lay it down with the handle towards the surface and the broken glass facing you. Remove the 4 screws on the broken glass side, the 2 screws holding the brackets on the bottom and the 2 screws on the top of the door. You will need to wiggle the inside cover off because there are 2 little clips at the top you need to get it off of the outer glass door. You should have 2 separate pieces, the outer glass of the door and the inner tempered glass and sheet metal portion of the door. Set the outer glass door aside, somewhere safe, as you really don't want to have to reorder that part too! From there you can lay the door down with the broken inner door glass towards the work surface. Remove the screws and good pieces of glass and lay them down in the order you take them out. This helps putting them back together later. Keep the pieces together in sets so you know which set goes to each section. There should be 3 pieces of glass total in the assembly. You remove the screws and the 2 good pieces of glass. The inside door glass is accessible under a large piece of sheet metal held in place by little flanges cut into it. You can remove this sheet metal panel piece by wiggling it out away from under the hinges and away from the hinge end. There is a piece of insulation under there as well. Make sure you reseat it correctly when you put it all back together. If you don't it will stick out, and make things hard to line up. Pull the broken glass out, Put the new glass in and replace the sheet metal panel. At this point I would suggest putting the four screws you took out at the very beginning from the inside of the door back in. They keep the 2 hinge assemblies in place and they will be harder to line up if you don't. You need to work from the bottom side up but it's pretty easy to get the 4 screws back in. Don't be afraid to wiggle the pieces around so you can line up the holes. They need to line up so that the hinges line up back to the oven. Reverse how you took the other glass pieces out and put the door back together. Put the front glass piece back on and secure it in place with the bottom door brackets and screws and the top 2 screws. Lift the door unit back up by the handle and place it in the slots for the hinges exactly the way you removed it. You will feel it sort of catch when you pull the door open slowly. Remove the Allen wrenches and you are done.

Remove rear panel - remove sensor from inside - unplug from rear - reverse to install - did not fix problem

Order part from this site was very easy. It matched perfectly and I had no problem installing it

Quickly

It was a matter of swapping out the old door with new door. In all, it was a snap . Around 10 screws to take it apart and a few brackets to hold it all together.

With just the removal of a few screws I was able to replace the glass with the side benefit of cleaning the outter glass that had gotten dirty over the years with use. This is a simple project that all can complete.