Windshield: Service and Repair
Interior Auto Glass Cut-Out Knife Kit:
Special Tool(s)
REMOVAL
1. Remove the windshield wiper pivot arms.
2. Remove the cowl top vent panel.
3. Drill out the rivets, and remove the windshield glass stops.
4. Remove the inside rear view mirror.
5. Remove (pull off) the RH and LH A-pillar mouldings.
6. Lower the front portion of the roof trim panel.
7. Lubricate the urethane sealant with ECL-784 lubricant (10:1 ratio of water to soap), to aid the Interior Glass Cut-Out Knife Kit when cutting the urethane sealant.
8. Insert the Interior Glass Cut-Out Knife into the urethane sealant at the upper center of the vehicle interior, and work toward the bottom corners.
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING THE HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE.
CAUTION: To prevent damage to the windshield header seal, turn the blade so that the flat side is against the pinch weld.
9. Insert the Interior Glass Cut-Out Knife into the bottom center of the urethane sealant on the vehicle exterior, and work toward the corners.
NOTE: Support the windshield glass, to prevent the glass from dropping, before cutting the bottom edge of the urethane sealant.
10. Carefully remove the windshield glass from the vehicle.
CAUTION: Removing the glass requires more than one technician.
11. Remove the windshield header seal.
12. Trim the remaining urethane on the pinch weld to within the specification.
- The old urethane must be smooth and free of cuts and contamination.
INSTALLATION
1. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that could cause glass damage.
2. Apply Urethane Body Primer WSB-M2G23C (black) to any exposed metal on the pinch weld.
- Do not apply the primer to the existing urethane bead.
- Let the primer dry for a minimum of 6-10 minutes before proceeding.
3. If re-installing the same windshield glass, remove all remaining traces of urethane sealant.
4. Install the windshield header seal on the windshield glass.
5. Properly align the windshield glass to the body, mark the windshield glass, and remove the windshield glass from the vehicle.
1 Place the windshield glass in the opening, and center it from top to bottom and side to side with about equal clearance on all sides.
2 Make alignment marks on each of the four sides of the windshield glass.
3 Remove the windshield glass from the vehicle, and place it inside up.
6. Clean the inside of the windshield glass with an alcohol-free cleaner.
7. Apply Urethane Glass Primer Wipe WSB-M5B280-C2 (red) to the entire inside perimeter of the windshield glass. Wipe off immediately after each application.
NOTE: Apply with deliberate strokes, making sure not to overlap the applied area.
8. Apply Urethane Glass Primer WSB-M2G314-B (black) to the entire inside perimeter of the windshield glass. Allow a minimum of 5 minutes drying time.
9. Apply an 11-mm (0.43-inch) wide bead of Urethane High Viscosity Adhesive WSB-M2G316-B to the entire primed area of the windshield glass.
NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane sealant.
10. Position the windshield glass on the vehicle pinch weld, aligning it with the marks.
CAUTION: After replacing the urethane-installed glass, the vehicle must not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane can adversely affect the strength of the urethane sealant bond.
NOTE: Before installing the windshield glass, open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed.
11. Position the windshield glass stops on the vehicle. Make sure the windshield glass is aligned and rivet the stops in position, using a 385974-S rivet.
12. Wipe off any excess urethane sealant and apply a 6-mm (0.23-inch) bead of Pumpable Foam Dam ESB-M46309-A between the windshield header seal and the urethane sealant.
13. Fill the cavities between both the LH and RH sides of the windshield header seal and the sheet metal, using RTV Sealer ESB-M4G92-A for a total length of 50 mm (2 inches) from the base of the A-pillars.
14. Install the inside rear view mirror.
15. Install the roof trim panel.
16. Install (push on) the LH and RH A-pillar mouldings.
17. Install the cowl top vent panel.
18. Install the windshield wiper pivot arms.