Windshield: Service and Repair
WINDSHIELDDESCRIPTION
Windshields are made of two pieces of glass with a plastic inner layer. Windshields and selected stationary glass are structural members of the vehicle. The windshield glass is bonded to the windshield frame with urethane adhesive.
Windshields and other stationary glass protect the occupants from the effects of the elements. Windshields are also used to retain some airbags in position during deployment.
The windshield is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the moldings are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and moldings from the parts supplier.
RECOMMENDED TOOLS AND ADHESIVE
- Fein(R) Power Cutout Knife
- Equalizer(R) Magnum, Interior Auto Glass Cut Out Knife
ADHESIVE, PRIMER AND CLEANER
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.
RECOMMENDED TOOLS AND ADHESIVE
The following urethane adhesive systems are OEM certified and conform to the FMVSS 212 windshield retention standard and the FMVSS 216 roof crush standard.
REMOVAL
COUPE - EXTERIOR METHOD
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.
1. Remove inside rear view mirror.
2. Remove windshield wiper arms.
3. Remove cowl cover.
4. Place protective covers over instrument panel and hood
5. Remove windshield A-pillar trim and header.
6. Using a sharp cold knife (1), 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.
7. Remove windshield from vehicle.
COUPE - INTERIOR METHOD
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.
1. Remove inside rear view mirror.
2. Remove instrument panel top cover, refer to Instrument Panel.
3. Remove A-pillar trim.
4. Place protective covers over instrument panel and hood.
5. Using a reciprocating saw or knife (1), 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.
6. Remove windshield from vehicle.
CONVERTIBLE - EXTERIOR METHOD
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.
1. Remove inside rear view mirror.
2. Remove windshield wiper arms.
3. Remove cowl cover.
4. Place protective covers over instrument panel and hood.
5. Remove windshield header and A-pillar trim and header.
6. Using a sharp cold knife (1), 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.
7. Remove windshield (2) from vehicle.
CONVERTIBLE - INTERIOR METHOD
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.
1. Remove inside rear view mirror.
2. Remove instrument panel top cover, refer to Instrument Panel.
3. Remove header and A-pillar trim.
4. Place protective covers over instrument panel and hood.
5. Using a reciprocating saw or cold knife (1), 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.
6. Remove windshield (2) from vehicle.
INSTALLATION
COUPE
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. Verify support spacers in windshield opening. If not present, install spacers as indicated.
2. Verify squeak tape (2) on roof panel hooks. If not present, install squeak tape. Section C-C.
3. Verify replacement windshield has squeak tape (2) and anti-squeak lube (3). If not present, install squeak tape and anti-squeak lube.
4. Position windshield into opening by installing encapsulation locator pin (1) then loading the encapsulation hooks (2) onto the panel hooks.
5. Verify glass encapsulation lays evenly along roof panel and that there is no gapping of the encapsulation squeak tape to the windshield opening. If gaps are present, the pinch weld fence must be formed to the shape of the new glass.
6. Remove replacement windshield from opening.
7. 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.
8. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
9. Apply Glass Prep adhesion promoter 25 mm (1 inch) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible.
10. Apply Glass Primer 25 mm (1 inch) wide around perimeter of windshield. Allow at least three minutes drying time.
11. Apply a bead of urethane (4) on windshield glass as indicated.
12. With the aid of a helper, position the windshield over the windshield opening and install encapsulation locator pin then load encapsulation hooks onto the roof panel hooks (3).
13. Push windshield into opening until no gap encapsulation lays evenly along roof panel and there is no gapping of encapsulation squeak tape to the windshield opening 14. Clean excess urethane (4) from exterior with Mopar, Super clean or equivalent.
15. Apply tape to windshield assembly as required if gap exists around windshield opening.
16. After urethane has cured, remove tape strips and water test windshield to verify repair.
17. Install cowl covers.
18. Install inside rear view mirror.
19. Allow urethane to cured for 10 - 12 hours. Remove tape strips and water test windshield.
CONVERTIBLE
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. Verify support spacers in windshield opening. If not present, install spacers as indicated.
2. Position windshield into opening by contacting header spacers then loading the glass hooks onto the panel hooks.
3. Verify glass encapsulation lays evenly along roof panel and that there is no gapping of the glass to spacers in the windshield opening. If gaps are present, the pinch weld fence must be formed to the shape of the new glass.
4. Remove replacement windshield from opening.
5. 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.
6. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
7. Apply Glass Prep adhesion promoter 25 mm (1inch) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible.
8. Apply Glass Primer 25 mm (1 inch) (2) wide around perimeter of windshield. Allow at least three minutes drying time.
9. Apply a bead of urethane (4) on windshield glass as indicated.
10. With the aid of a helper, position the windshield over the windshield opening and install contacting header spacers then load glass hooks onto the roof panel hooks (2).
11. Push windshield into opening until there is glass to spacers in the windshield opening.
12. Clean excess urethane from exterior with Mopar(R) Super Kleen or equivalent.
13. Apply tape (2) to windshield assembly as required if gap exists around windshield opening.
14. After urethane has cured, remove tape strips and water test windshield to verify repair.
15. Install cowl covers, A-pillar trim and header trim molding.
16. Install inside rear view mirror.
17. Allow urethane to cured for 10 to 12 hours. Remove tape strips and water test windshield.