Back Window Glass: Service and Repair
Rear Window Replacement
NOTE:
- Put on gloves to protect your hands.
- Wear eye protection while cutting the glass adhesive with a piano wire.
- Use seat covers to avoid damaging any surfaces.
- Do not damage the rear window defogger grid lines or the terminals.
1. Remove these items:
- Tailgate lower trim panel
- Tailgate spoiler Trim Service and Repair
- Rear window wiper motor Rear Window Wiper Motor Replacement
2. Remove the lower rubber dam (A) from the edge of the rear window. If necessary, cut the rubber dam with a utility knife.
3. Disconnect the rear window defogger connectors (A).
4. If the original rear window will be reinstalled, make alignment marks across the glass and the body with a grease pencil.
5. Apply protective tape along the inside and outside edges of the tailgate. Make a hole with an awl through the adhesive from inside the vehicle at the corner portion of the rear window. Push the piano wire through the hole, and wrap each end around a piece of wood.
6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window (B) as possible to prevent damage to the tailgate, and carefully cut through the adhesive (C) around the entire rear window.
Cutting positions
7. Carefully remove the rear window.
8. Scrape smooth the old adhesive with a knife until there is a thickness of about 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange:
- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding
- Remove the fasteners from the tailgate.
9. Clean the body bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the surface.
10. If you are reinstalling the original rear window, scrape off all of the old adhesive, the fasteners and the rubber dams from the rear window with a putty knife. Clean the bonding surface on the inside face and the edge of the rear window with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
11. Apply glass primer to the upper clip mounting areas on the rear window (A), and let it dry. Remove the adhesive backing and attach the upper clips (B), the fasteners (C), the upper rubber dam (D), and the side rubber dams (E) to the inside face of the rear window as shown.
- Make sure the upper clips, the fasteners, and the upper rubber dam line up with alignment marks (F).
- With the printed dots (G) on the rear window as a guide, attach the side rubber dam to both side portions of the rear window.
- Be careful not to touch the rear window where the adhesive will be applied.
12. Apply glass primer to the edge of the rear window (A) where the lower rubber dam will be attached as shown. Attach the lower rubber dam (B) with adhesive tape (C) to the edge of the rear window:
- Fit both lower corner portions of the lower rubber dam to the rear window, then install it into place.
- After installing the lower rubber dam, cut the ends (D) of the lower rubber dam as shown.
- Be careful not to touch the rear window where the adhesive will be applied.
13. Attach the fasteners with adhesive tape to the tailgate on both sides as shown.
14. If you are installing a new rear window (A), set the rear window in the opening, and center it. Make alignment marks (B) across the rear window and the body with a grease pencil at the four points shown:
- Make sure the pins (C) of both upper clips (D) contact with the edge of the body holes.
- Be careful not to touch the rear window where the adhesive will be applied.
15. Remove the rear window.
16. Apply a light coat of glass primer to the rear window (A) along the edge of the rubber dams (B) as shown, then lightly wipe it off with gauze or cheesecloth:
- Do not apply body primer to the rear window, and do not mix up the body primer applicator and the glass primer applicator.
- Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed.
- Keep water, dust, and abrasive materials away from the primed surface.
17. Carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the body primer dry for at least 10 minutes:
- Do not apply body primer to any remaining original adhesive on the flange.
- Be careful not to mix up the body primer applicator and the glass primer applicator.
- Never touch the primed surfaces with your hands.
18. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.
19. Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) to the rear window (B) along the edge of the rubber dams (C) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
20. Hold the rear window with suction cups over the opening, align it with the alignment marks you made in step 4 or step 14, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
21. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
22. Wait at least an hour for the adhesive to dry, then spray water over the rear window and check for leaks. Mark leaking areas, and let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
23. Reinstall all removed parts.
NOTE: Advise the client not to do the following things for 2 to 3 days:
- Slam the doors with all the windows rolled up.
- Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).