Heated Glass Element: Service and Repair
GRID LINE AND TERMINAL REPAIR
WARNING: Materials contained in the Repair Kit (Part Number 04549275) may cause skin or eye irritation. The kit contains epoxy resin and amine type hardener, which are harmful if swallowed. Avoid contact with the skin and eyes. For skin contact, wash the affected areas with soap and water. For contact with the eyes, flush with plenty of water. Do not take internally. If taken internally, induce vomiting and call a physician immediately. Use with adequate ventilation. Do not use near fire or flame. Contains flammable solvents. Keep out of the reach of children. Failure to follow the warnings could result in possible personal injury or death.
REAR WINDOW DEFOGGER GRID LINE REPAIR
Repair of the rear glass heating grid lines and bus bars can be accomplished using the Mopar(R) Rear Window Defogger Repair Kit (Part Number 04549275) or equivalent.
1. Mask the repair area with masking tape (3) so that the conductive epoxy can be applied neatly. Extend the epoxy application onto the grid line (2) or the bus bar on each side of the break (1).
2. Follow the instructions in the repair kit for preparing the damaged area.
3. Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the packaging. Fold the package in half and cut the center corner to dispense the epoxy.
4. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19 millimeters (0.75 inch).
5. Carefully remove the masking tape or template.
CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a heat gun, or the glass may fracture.
6. Allow the epoxy to cure 24 hours at room temperature, or carefully use a heat gun for 15 minutes. When using a heat gun, hold it approximately 25.4 centimeters (10 inches) from the repair and do not allow the glass surface to exceed 204° C (400° F).
7. After the epoxy has properly cured, verify EBL operation.
REAR WINDOW DEFOGGER TERMINAL REPAIR - HARD TOP MODELS
Repair of the rear glass heating grid terminal(s) on hard top models can be accomplished using the Mopar(R) Rear Window Defogger Repair Kit (Part Number 04549275) or equivalent.
8. If either grid terminal is broken, remove the portion of the broken terminal remaining in the heating grid wire harness connector(s).
9. Mask the areas so the conductive epoxy can be extended onto the adjacent grid line(s) as well as the bus bar.
10. Apply a thin layer of conductive epoxy to the area where the terminal(s) were fastened and to the adjacent grid line(s).
NOTE: To prevent the terminal(s) from moving while the epoxy is curing, a wedge or clamp must be used.
11. Apply a thin layer of conductive epoxy on the grid terminal(s) and properly orient the terminal(s) at the desired location(s).
12. Carefully remove the masking tape.
CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a heat gun, or the glass may fracture.
13. Allow the epoxy to cure 24 hours at room temperature, or carefully use a heat gun for 15 minutes. When using a heat gun, hold it approximately 25.4 centimeters (10 inches) from the repair and do not allow the glass surface to exceed 204° C (400° F).
NOTE: To ensure proper installation, do not attach the wire harness connector(s) to the terminal(s) until the epoxy is completely cured.
14. After the conductive epoxy has properly cured, remove the wedge or clamp from the grid terminal(s), reconnect the heating grid wire harness connector(s) and verify EBL operation.
REAR WINDOW DEFOGGER TERMINAL REPAIR - CONVERTIBLE MODELS
CAUTION: Do not use a flame type solder gun or an electric solder gun rated greater than 500 watts or damage to the glass may occur.
NOTE: If either rear window defogger heating grid terminal is damaged or separated from the rear window on convertible models, a new terminal must be securely fastened to the rear window defogger bus bar by soldering.
Repair of the rear window heating grid terminal(s) on convertible models can be accomplished using the Mopar(R) Heated Rear Window Terminal Kit (Part Number 05093179).
15. If either grid terminal is broken, remove the portion of the broken terminal remaining in the heating grid wire harness connector(s).
CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a solder gun, or the glass may fracture.
16. If either grid terminal is broken and a portion of the broken terminal is still attached to the rear window defogger bus bar, apply heat with a solder gun to the portion of the terminal on the glass until the solder starts to flow. Remove the terminal and carefully smooth the solder on the bus bar.
NOTE: Wait five minutes for the glass to cool after applying heat with a solder gun before proceeding.
NOTE: Use care when cleaning the mating surfaces. Excessive abrasion may wear away the copper grid surface causing grid continuity to be lost.
17. Clean the mating surfaces on the grid bus bar and the new terminal(s) with "000" Extra Fine Steel Wool or an equivalent.
NOTE: The terminal attaching clip(s) must face outboard. Failure to reorient the terminal(s) may result in an additional failure.
18. Properly orient the new terminal(s) with the attaching clip facing outboard in the original location(s) on the grid bus bar and hold the terminal(s) with a metal pick or other suitable pointed tool.
CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a solder gun, or the glass may fracture.
NOTE: New rear window defogger terminals are pre-soldered and fluxed. Do not reuse a terminal if it has been previously heated.
Place the solder gun onto the new terminal(s) and heat the terminal until the solder flows. Remove the solder gun and continue to hold the terminal in the correct position for an additional 5 seconds.
19. Allow the solder to cool for 10 minutes.
NOTE: To ensure proper installation, do not attach the wire harness connector(s) to the terminal(s) until the solder is completely cooled.
20. After the solder has cooled, reconnect the wire harness connector(s) and verify EBL operation.