Windshield: Service and Repair
Windshield Glass
Removal
1. Remove the windshield wiper pivot arms. For additional information, refer to Wiper and Washer Systems.
2. Remove the A-pillar trim panel.
3. Remove the sun visors and clips.
4. Remove the interior rear view mirror. For additional information, refer to Mirrors.
5. Lower the front portion of the headliner and block with a suitable material.
6. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld area.
7. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or otherwise damage the pinch weld during glass removal.
NOTE: Lubricate the existing urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting.
NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement windshield glass.
Insert the Deluxe Windshield Removal Tool at the upper center of the windshield glass and work toward the bottom corners.
8. Using The Pumper, distance the windshield glass from the body.
9. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive and carefully remove the windshield glass and place on a stable work surface.
Installation
1. Dry fit the windshield glass on the existing urethane adhesive bead on the pinch weld.
- Position the windshield glass on the pinch weld.
- Center the windshield glass in the opening.
- Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
- Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass stop blocks, if equipped) on the windshield glass and the body.
2. After the dry-fit alignment, remove the glass from the windshield opening and place on a stable work surface with the interior side of the glass facing up.
3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane adhesive on the pinch weld.
4. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during windshield removal.
5. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive bead.
6. Clean the inside of the glass surface with glass cleaner.
7. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in this procedure.
If installing a new windshield glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
8. Cut the urethane adhesive applicator tip to specification.
9. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and a continuous bead.
NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld starting and ending at the bottom of the windshield near the center, making sure there are no gaps in the bead.
WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.
10. Using the alignment marks made previously, position the windshield glass on the pinch weld.
11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
Check the installation for air and water leaks through the urethane adhesive bond and add urethane adhesive as necessary.
12. Reposition the headliner.
13. Install the inside rear view mirror. For additional information, refer to Mirrors.
14. Install the sun visors and clips.
15. Install the A-pillar trim panel.
16. Install the windshield wiper pivot arms. For additional information, refer to Wiper and Washer Systems.