Rear Window Replacement

Rear Window Replacement

Tools Required
* J 24402-A Glass Sealant Remover (Cold Knife)
* J 39032 Stationary Glass Removal Tool
* Urethane Adhesive Kit GM P/N 12346392 or Equivalent
* Isopropyl Alcohol or Equivalent
* Cartridge-type Caulking Gun
* Commercial-type Utility Knife
* Razor Blade Scraper
* Suction Cups
* Plastic Paddle

Removal Procedure

Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and inner trim of the window.


1. Remove the rear window garnish moldings. Refer to Rear Window Garnish Molding Replacement (Base Trim) Rear Window Garnish Molding Replacement (Base Trim)Rear Window Garnish Molding Replacement (Up-Level Trim) Rear Window Garnish Molding Replacement (Up-Level Trim).

Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

2. Use safety glasses and gloves.

Important: Do not use the J 24402-A if the glass is not broken and is going to be reused as the molding may be damaged.


Important: The stationary window reveal molding retains the urethane adhesive in the cavity between the body and the opening. If the stationary window reveal molding is damaged by cutting it too close to the window surface, replace the window.


3. If the glass is already broken, the J 24402-A may be used to remove the window.





Important: Keep the cutting edge of the tool against the window when removing. This will allow the urethane adhesive to be separated from the window and leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.


4. Use the J 24402-A or J 39032 tool in order to cut the window from the pinchweld flange. Do this from inside the vehicle to protect the outer surface of the paint.
5. With an assistant standing outside of the vehicle, push the window out from the vehicle.

Installation Procedure

1. Verify all primers and urethane adhesive are within expiration dates.
Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392 (Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

2. Inspect the following components for the causes of a broken rear window:

* The flange of the rear window opening
* The rear window reveal molding

3. Inspect for any of the following problems in order to help prevent future breakage of the rear window:

* High weld
* Solder spots
* Hardened spot weld sealer
* Any other obstruction or irregularity in the pinchweld flange.

Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are required, the pinchweld flange must be refinished in order to restore the bonding area strength. If paint repairs are required, mask the flange bonding area prior to applying the color coat in order to provide a clean primer only surface. Materials such as BASF DE17(R), DuPont 2610(R), Sherwin-Williams PSE 4600 and NP70(R) and Martin-Semour 5120 and 5130(R) products are approved for this application.


4. After repairing the opening as indicated, perform the following steps:

1. Inspect the condition of the rear window opening and the adhesive bead to determine which installation method should be used. Refer to Short Method Description Short Method Description or Extended Method Description Extended Method Description for the guidelines.
2. Remove no more of the urethane adhesive from the pinchweld than necessary in order to maintain the original shape. This will ensure the proper clearance between the rear window and the pinchweld flange.
3. Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.
4. Clean around the edge of the inside surface of the rear window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

5. After repairing the opening as indicated, shake the pinchweld primer (black #3) for at least 1 minute.





Caution: Failure to prep the area prior to the application of primer may cause insufficient bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

6. Use a new dauber to apply the pinchweld primer (black #3) to the surface (1) of the bonding area on the body only.
7. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.
8. With the aid of an assistant, dry fit the stationary window into the opening.
9. Use masking tape in order to mark the location of the stationary window in the opening.
10. Slit the masking tape at the top edge of the stationary window.




11. Remove the stationary window from the opening.
12. Place the stationary window inside up on a clean, protected surface.
13. If the original window is being reused, remove all but a thin film of the existing urethane adhesive from the window surface using a utility knife or razor blade scraper.
14. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.
15. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the existing bead of adhesive from the pinchweld flange.

Important: Do not remove all traces of the adhesive. Remove all mounds or loose pieces of urethane adhesive.


16. Shake the pinchweld primer (black #3) for at least one minute.
17. Use a new dauber to apply the primer to the surface of the pinchweld flange.
18. Allow the glass primer to dry for approximately 10 minutes.

Important: Use the following procedure:


19. Use care when applying the stationary window prep (clear #1) in order to prevent the window prep from running into the vision area of the stationary window. This primer dries almost instantly and may stain the viewing area of the window if not applied evenly.




20. If installing a new non encapsulated window:

1. Use a new dauber, to apply the stationary window prep (clear #3) approximately 10 mm to 16 mm (3/8 in to 5/8 in) around the entire perimeter of the window inner surface.
2. Apply stationary window prep (clear #1) to any exposed edges of the window.
3. Wipe the glass primed area immediately with a clean lint free cloth.
4. Shake the glass primer (black #2) for at least one minute.
5. If installing a new encapsulated window:
Use a new dauber, in order to apply the window prep (clear #2) to the area approximately 10 mm to 16 mm (3/8 in to 5/8 in) around the entire perimeter of the glass inner surface of the primer/bonding areas). The primer is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.
6. Allow the glass primer to dry for approximately 10 minutes.




21. If using the short method, cut the tip of the applicator nozzle in order to provide a bead of 6.0 mm (1/4 in).




22. If using the extended method, cut the applicator nozzle in order to provide a bead 10.5 mm (0.14 in) wide and 10.5 mm (0.14 in) high.




23. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.
24. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.




25. When using the extended method, use the edge of the stationary window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the (2) urethane adhesive to the inner surface of the (3) stationary window.
26. Use suction cups and, with the aid of an assistant, install the stationary window into the opening.




27. Align the tape on the stationary window and the body.
28. Press the stationary window firmly into place.
29. Tape the stationary window to the body in order to minimize movement.




30. Clean any excess urethane adhesive from the body.





Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.


31. Use a soft spray of warm water in order to immediately water test the windshield window.
32. Inspect the stationary window for leaks.
33. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
34. Retest stationary window for leaks.

Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

* For the moisture-curing type of urethane adhesive, allow a minimum of 6 hours at 21°C (70°F) or greater and with at least 30 percent relative humidity. Allow at least 24 hours for the complete curing of the urethane adhesive.
* For the chemical-curing type of urethane adhesive, allow a minimum of 1 hour.

Do NOT physically disturb the repair area until after these minimum times have elapsed.

35. The following conditions must be maintained to properly cure the urethane.

1. Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.
2. Do not drive the vehicle until the urethane adhesive is cured.
3. Do not use compressed air in order to dry the urethane adhesive.

Important: Inspect the stationary window for leaks.


36. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
37. Retest stationary window for leaks.
38. In order to properly cure the urethane adhesive, do the following:
39. Install the rear window garnish moldings. Refer to Rear Window Garnish Molding Replacement (Base Trim) Rear Window Garnish Molding Replacement (Base Trim)Rear Window Garnish Molding Replacement (Up-Level Trim) Rear Window Garnish Molding Replacement (Up-Level Trim).
40. Remove the protective coverings and tape from the vehicle.