Cowl: Service and Repair

Windshield Panel Replacement - Lower

Removal Procedure
Caution: Refer toApproved Equipment for Collision Repair Caution in Cautions and Notices.

Important: When replacing panels that involve servicing of stationary glass, refer toUrethane Adhesive Installation of Stationary Windows (Urethane Adhesive Installation of Stationary Windows) before performing any priming or refinishing.



1. Disable the SIR system. Refer toSIR Disabling and Enabling Zones in SIR.
2. Disconnect the negative battery cable. Refer toBattery Negative Cable Disconnect/Connect Procedure in Engine Electrical.




3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer toDimensions - Body (Long Wheelbase) ()Dimensions - Body (Short Wheelbase) ()Dimensions - Body (Engine Compartment) ()Dimensions - Body (Body Side) () .
Caution: Refer toFoam Sound Deadeners Caution in Cautions and Notices.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer toAnti-Corrosion Treatment and Repair () in Paint and Coatings.
6. Remove the windshield. Refer toWindshield Replacement (Removal and Replacement) .





Important: Do not damage any inner panels or reinforcements.


7. Locate and drill out all factory welds. Note the number and location of welds for installation of the new panel.




8. Remove the damaged panel.



Installation Procedure






Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (11/2 in) apart.


1. Drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original front panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M(R) Weld-Thru coating P/N 05916 or equivalent to all mating surfaces




4. Position the upper rail.




5. Plug weld accordingly.
6. Install the windshield. Refer toWindshield Replacement (Removal and Replacement) in Stationary Windows.




7. Clean and prepare all welded surfaces.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer toAnti-Corrosion Treatment and Repair () in Paint and Coatings.
9. Paint the repair area. Refer toBasecoat/Clearcoat Paint Systems (Basecoat/Clearcoat Paint Systems) in Paint and Coatings.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer toBattery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
12. Enable the SIR system. Refer toSIR Disabling and Enabling Zones in SIR.