Windshield: Service and Repair

WINDSHIELD

The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended.

WINDSHIELD REMOVAL - EXTERIOR METHOD

1. Remove inside rear view mirror.
2. Remove windshield wiper arms.
3. Remove cowl cover.
4. Remove A-pillar trim panels.
5. Disconnect wire connectors to windshield defroster grid.
6. Place protective covers over instrument panel and hood.
7. Remove windshield molding. Using pliers, pull outward on molding at the bottom of A-pillars.






8. Using a sharp cold knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences
A power cutting device can be used if available.
10. Remove windshield from vehicle

WINDSHIELD REMOVAL - INTERIOR METHOD

1. Remove inside rear view mirror.
2. Remove instrument panel top cover.
3. Remove A-pillar trim covers.
4. Disconnect wire connectors to windshield defroster grid.
5. Place protective covers over instrument panel and hood.
6. Using a reciprocating or oscillating power knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences. Refer to instructions provided with the equipment being used.
7. Remove windshield from vehicle.

WINDSHIELD INSTALLATION

CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result.

Allow the urethane at least 24 hours to cure before returning the vehicle to use.

To avoid stressing the replacement windshield, the urethane bonding material on the windshield fence should be smooth and consistent to the shape of the replacement windshield. The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening.

1. Place replacement windshield into windshield opening and position glass in the center of the opening against the compression spacers.
2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass.
3. Remove replacement windshield from windshield opening.






4. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart.

WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT.

5. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
6. Install molding to perimeter of windshield.
7. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visble.
8. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time.
9. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence.
10. Apply pinch weld primer 19 mm (0.75 in.) wide around the windshield fence. Allow at least three minutes drying time.






11. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening.
12. Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence.
13. With the aid of a helper, position the windshield over the windshield opening.
14. Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward until molding is flush to roof line and A-pillars.
15. Clean access urethane from exterior with Mopar� Super Kleen or equivalent.
16. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures.
17. Engage wire connectors to windshield defroster grid.
18. Install A-pillar trim panels.
19. Install cowl cover and wipers.
20. Install inside rear view mirror.
21. After urethane has cured, remove tape strips and water test windshield to verify repair.