Back Window Glass: Service and Repair

Rear Window Replacement

NOTE:

- Wear eye protection while cutting the glass adhesive with a piano wire.
- Put on gloves to protect your hands.
- Use seat covers to avoid damaging any surfaces.
- Do not damage the rear window defogger grid lines, the window antenna grid lines, or the terminals.

1. Remove these items:

- Tailgate lower trim panel
- Tailgate spoiler Service and Repair
- Rear window wiper motor

2. Remove rubber dam B from the edge of the rear window. If necessary, cut the rubber dam with a utility knife.






3. Disconnect the rear window defogger terminals (A).






4. If the original rear window will be reinstalled, make alignment marks across the rear window and body with a grease pencil.

5. Apply protective tape along the inside and outside edges of the body. Make a hole with an awl or similar tool through the adhesive from inside the vehicle at the corner area 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 the original adhesive smooth to a thickness of about 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange with a putty knife:

- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove the fasteners from the body.

9. Clean the tailgate bonding surface with a sponge dampened with isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the clean surface.

10. If a new rear window is to be installed, install the rear wiper seal (A) to the rear window (B) with its alignment mark (C) being aligned with the mark (D) on the rear window.





11. If the original rear window is to be reinstalled, check for a damaged rear wiper seal, and replace it with a new one.

12. If you are installing the original rear window, scrape off all of the original adhesive, the fasteners, and the rubber dams from the rear window with a putty knife. Clean the inside face and the edge of the rear window with alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil, and grease.

13. Attach the rubber dams A, B, and the fasteners (C, D) with adhesive tape to the inside face of the rear window (E) as shown. Before installing rubber dam B, apply primer to the area where the adhesive tape will be applied to the inside face of the rear window:

- Make sure the fasteners and rubber dams line up with the alignment marks (F).
- Cut excess rubber dam B along the upper edge of the rear window.
- Be careful not to touch the rear window where adhesive will be applied.


















14. Attach the fasteners (A, B) with the adhesive tape to the tailgate as shown.










15. Set the rear window (A) in the opening, and center it. Make alignment marks (B) across the rear window and body with a grease pencil at the four points shown:

NOTE: Be careful not to touch the rear window where adhesive will be applied.





16. Remove the rear window.

17. Apply a light coat of glass primer around the edge of the rear window (A) and along the rubber dams (B) as shown, then lightly wipe it off with gauze or cheesecloth:

- With the printed dots (C) on the rear window as a guide, apply the glass primer to both side area of the rear window.
- Do not apply body primer to the rear window, and do not mixed up the body ad glass primer applicators.
- 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.





18. Carefully apply a light coat of body primer to any exposed paint or metal around the flange where the 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 and glass primer applicators.
- Never touch the primed surfaces with your hands.





19. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.






20. 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:

- Use the printed dots (D) on the rear window as a guide, apply the adhesive to both side areas of the rear window.
- Apply the adhesive within 30 minutes after applying the glass primer.
- Make a slightly thicker bead at each corner.





21. Hold the rear window with suction cups over the opening, align it with the alignment marks you made in step 15, 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.

22. Remove the excess adhesive with a putty knife or shop towel dampened with isopropyl alcohol.

23. Wait at least an hour for the adhesive to dry, then spray water over the rear window, and check for leaks. Mark the leaking area, 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.

24. Reinstall all remaining 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).