Back Window Glass: Service and Repair
Rear Window ReplacementNOTE:
- Put on gloves to protect your hands.
- Use seat covers to avoid damaging any surfaces.
- Wear eye protection when removing the glass with piano wire.
- Do not damage the rear window defogger grid lines, window antenna grid lines, and terminals.
1. Remove these items:
- Trunk lid
- C-pillar trim
- Rear shelf
- High mount brake light
2. Remove the window antenna terminal cover (A) from the window antenna terminal base (B), and disconnect the window antenna connector (C).
3. If the old rear window is to be reinstalled, make alignment marks across the glass and body with a grease pencil.
4. Disconnect the rear window defogger connectors (A).
5. Remove the molding (A) from the edge of the rear window (B). If necessary, cut the molding with a utility knife.
6. Pull down the rear portion of the headliner. Take care not to bend the headliner excessively, as you may crease as break it.
7. Apply protective tape (A) along the inside and outside edges of the body as shown. Using an awl, make a hole through the adhesive (B) from inside the vehicle. Push a piece of piano wire (C) through the hole, and wrap each end around a piece of wood.
8. 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 body, and carefully cut through the adhesive (C) around the entire rear window.
9. Carefully remove the rear window.
10. With a putty knife, scrape the old adhesive smooth to 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.
- Mask off surrounding surfaces before painting.
- Remove the fasteners from the body.
11. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface.
12. If the old rear window is to be reinstalled, use a putty knife to scrape off all of the old adhesive and the fasteners from the rear window. Clean the shaded portion of the rear window (A) with alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil, and grease.
13. Glue the clips (A) with adhesive tape (3M 4216, or equivalent) and spacers with adhesive tape (3M 5357, or equivalent) (B) to the inside face of the rear window as shown. If necessary, apply primer (3M N-200, or equivalent) to the areas where the window antenna terminal base (C) will be glued, then glue the base with adhesive tape (3M 4211, or equivalent) on:
- Be sure the fasteners (and window antenna terminal base cover) line up with the alignment marks (D).
- Be careful not to touch the rear window where adhesive will be applied.
14. Apply the adhesive tape (A) (3M 4216, or equivalent) to the edge of the rear window (B):
- Be sure the adhesive tape lines up with the alignment marks (C).
- Be careful not to touch the rear window where adhesive will be applied.
15. Glue the molding (A) around the edge of the rear window (B):
- Be sure the joint (C) lines up with the alignment mark (D).
- Be careful not to touch the rear window where adhesive will be applied.
16. Install the clips to the body.
17. Set the rear window in the opening, and center it. Make alignment marks (A) across the rear window and body with a grease pencil at the four points shown. Be careful not to touch the rear window where adhesive will be applied.
18. Remove the rear window.
19. With a sponge, apply a light coat of glass primer along the edge of the rear window (A) and molding (B) as shown, then lightly wipe it off with gauze or cheesecloth:
- Do not apply body primer to the rear window, and do not get body and glass primer sponges mixed up.
- 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.
20. With a sponge, apply a light coat of body primer to the original adhesive remaining around the rear window opening flange. Let the body primer dry for at least 10 minutes:
- Do not apply glass primer to the body, and do not get glass and body primer sponges mixed up.
- Never touch the primed surfaces with your hands.
21. Before filling a cartridge, cut a "V" in the end of the nozzle (A) as shown.
22. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the rear window (B) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
23. Use suction cups to hold the rear window over the opening. Align it with the alignment marks you made in step 17, 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. Do not open or close the doors until the adhesive is dry.
24. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the rear window, use a soft shop towel dampened with alcohol.
25. Let the adhesive dry for at least 1 hour, then spray water over the rear window and check for leaks. Mark the leaking areas, 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.
26. Reinstall all remaining removed parts.
NOTE: Advise the customer 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).