Windshield: Service and Repair

WINDSHIELD

DESCRIPTION

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.

REMOVAL - JR-27 (Convertible) ONLY

EXTERIOR METHOD
1. Open convertible top.
2. Remove header/A-pillar weatherstrip from weatherstrip retainers.
3. Remove A-pillar weatherstrip retainer and molding.
4. Remove header weatherstrip/molding.
5. Mark top edge of the windshield glass at three locations on the header.
6. Remove windshield wiper arms.
7. Remove cowl cover.
8. Place protective covers over instrument panel and hood.

Fig. 1:

9. Using a sharp cold knife, cut urethane adhesive holding the windshield to the A-pillars, header and cowl pinch weld fences (Fig. 1). A power cutting device can be used if available.
10. Remove windshield from vehicle.

INTERIOR METHOD
1. Remove cowl cover.
2. Open convertible top.
3. Remove header/A-pillar weatherstrip from weatherstrip retainers.
4. Remove A-pillar weatherstrip retainer and molding.
5. Remove header weatherstrip/molding.
6. Mark top edge of the windshield glass at three locations on the header.
7. Remove header panel trim cover.
8. Remove header panel weatherstrip from channel.
9. Remove instrument panel top cover.
10. Remove A-pillar trim covers.
11. Place protective covers over instrument panel and hood.
12. 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.
13. Remove windshield from vehicle.

REMOVAL

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 cowl cover. Refer to Trim Panel.
3. Remove drip rail weatherstrips as necessary to gain access to screws holding windshield side moldings to A-pillars.
4. Remove screws holding windshield side moldings to A-pillars.

Fig. 2:

5. Remove windshield moldings. (Fig. 2) Pull outward on molding at the bottom of A-pillars using pliers.

Fig. 3:

6. Cut urethane bonding from around windshield using a suitable sharp cold knife. A pneumatic cutting device can be used if available. (Fig. 3)
7. Separate windshield from vehicle.

INSTALLATION - JR-27 (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.

NOTE: The JR 27 uses adjustable support spacers along the bottom. Once the support spacers are set, use care not to move them.

1. Place replacement windshield into windshield opening and position glass in the center of the opening against the support 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. Move the support spacers as necessary so that the top of the windshield aligns with the marks on the header, from the original windshield.
4. Place a piece of tape over the ratcheting portion of the bottom support spacer to prevent them from moving.
5. Repeat Step 3 and Step 4 for the opposite side of the windshield.

Fig. 4:

6. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation (Fig. 4).
7. Remove replacement windshield from windshield opening.

Fig. 5:

8. 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 (Fig. 5).

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

9. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
10. 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 visible.
11. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time.
12. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence.
13. Apply pinch weld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time.

Fig. 6:

14. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening at original locations (Fig. 6).
15. Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence.
16. With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers.

Fig. 7:

17. Slowly lower windshield glass to windshield opening fence. Push windshield inward until glass is flush to A-pillars (Fig. 7).
18. Clean access urethane from exterior with Mopar(R) Super Kleen or equivalent.
19. 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.
20. Install cowl cover and wipers.
21. Install inside rear view mirror to header.
22. After urethane has cured, remove tape strips and water test windshield to verify repair.

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 position and center in the opening against the support 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.

Fig. 8:

3. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation (Fig. 8).
4. Remove replacement windshield from windshield opening.

Fig. 9:

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 (Fig. 9).

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 molding to perimeter of windshield.
8. 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 visible.
9. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time.
10. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence.
11. Apply pinch weld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time.

Fig. 10:

12. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening (Fig. 10).
13. Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence.
14. With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers.
15. Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward molding is flush to roof line and A-pillars.
16. Clean access urethane from exterior with Mopar(R) Super Kleen or equivalent.
17. 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.
18. Install windshield side moldings and drip rail weatherstrips.
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.