Windshield Replacement
Removal ProcedureTools Required
- J 24402-A Glass Sealant (Cold knife) Remover
- J 39032 Stationary Glass Removal Tool
- J 25070 Heat Gun
- Isopropyl alcohol) or equivalent
- Cartridge-type caulking gun
- Commercial-type utility knife
- Razor blade scraper
- Suction cups
1. Place protective coverings around the window.
2. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems.
3. Remove the antenna, if equipped. Refer to Coaxial Cable Replacement in Entertainment.
4. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
5. Remove the rear view mirror. Refer to Rearview Mirror Replacement.
CAUTION: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.
6. Apply masking tape to the painted surfaces around the windshield in order to prevent paint damage and cover the defroster grille outlets.
7. Remove the door sealing weatherstrip from the upper pinchweld flange.
CAUTION: When working with any type of glass, use approved safety glasses and gloves to reduce the chance of personal injury.
8. Remove the windshield side reveal molding.
1. Grasp the lower corner of the windshield reveal molding with your hand and slowly pull the reveal molding away from the windshield.
2. If the windshield reveal molding will not release use a utility knife to cut around the windshield to remove the windshield reveal molding.
3. The windshield reveal molding fills the cavity between the body and windshield and can not be reused if stretched or damaged.
9. Remove the lower windshield supports (2) from the cowl panel (1), if equipped.
IMPORTANT: Keep the cutting edge of the tool against the windshield when removing. This will allow the urethane adhesive to be separated from the windshield and leave a base Of urethane on the pinchweld flange. The only suitable lubrication is clear water.
10. Use the J 24402-A or J 39032 tool in order to remove the windshield.
11. Remove the windshield from the vehicle with the aid of an assistant.
12. The following components may reveal the causes of a broken windshield:
- The flange of the windshield opening
- The windshield reveal molding
- The windshield
IMPORTANT: If corrosion of the pinch weld 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 DEI7 (R), DuPont 2610 (R), Sherwin-Williams PSE 4600 and NP70 (R) and Martin-Semour 5120 and 5130 (R) products are approved for this application.
13. Look for any of the following problems in order to help prevent future breakage of the windshield:
- High weld
- Solder spots
- Hardened spot weld sealer
- Any other obstruction or irregularity in the pinchweld flange
14. After repairing the opening as indicated, perform the following steps:
- Inspect the condition of the windshield opening and the adhesive bead to determine which installation method should be used. Refer to Short Method Description short method or Extended Method Description extended method for guidelines.
15. 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 windshield and the pinchweld flange.
16. Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.
17. Clean around the edge of the inside surface of the windshield with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.
Installation Procedure
CAUTION: When replacing stationary windows, Urethane Adhesive Kit GM PIN 1234639Z or a urethane adhesive system meeting GM Specification GM3651M, must be used 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.
After repairing the opening as indicated, perform the following:
1. Shake the pinchweld primer (black #3) for at least one minute.
CAUTION: Failure to prep 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.
2. Use a new dauber to apply the pinchweld primer (black #3) to the surface of the bonding area (1).
3. Allow the primer to dry for approximately 10 minutes, also check to ensure that all nicks and scratches are covered.
4. Install the lower windshield supports (2) to the cowl panel (1), if equipped.
5. Install the spacers and the VIN plate filler strip.
6. Install the reveal molding to the edge of the windshield. If the original reveal molding is damaged it must be replaced.
7. Install a new acoustic strip if needed.
8. With the aid of an assistant, dry fit the windshield in the opening in order to determine the correct way to position the windshield in the opening.
9. Use masking tape (1) in order to mark the location of the windshield in the opening.
10. Slit the masking tape at the top edge of the windshield.
11. Remove the windshield from the opening.
12. Place the windshield inside up on a clean, protected surface.
13. If the original windshield is being reused remove all but a thin film of the existing urethane adhesive from the windshield surface by using a clean utility knife or razor blade scraper.
14. Clean around the edge of the inside surface of the windshield 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 pinchweld primer to dry for approximately 10 minutes.
IMPORTANT: Use care when applying the glass prep (clear #1) in order to prevent the windshield prep from running into the vision area Of the windshield. This primer dries almost instantly, but may stain the viewing area of the windshield if not applied evenly.
19. Use a new dauber in order to apply glass prep (clear #3) to the area approximately 10 mm to 6 mm (3/8 in to 5/8 in) around the entire perimeter of the window inner surface.
20. Apply a second coat of the glass prep number (clear #1) to the same area of the glass.
21. Wipe the glass primed area immediately with a clean lint free cloth.
22. Shake the glass primer (black #2) for at least one minute.
23. Use a new dauber in order to apply the glass primer (black #2) to the same areas that glass prep (clear #i) was applied.
The glass primer (black #2) is good up to 8 hours after applying it to the glass (2). The primed surface of the glass must be kept clean.
24. Allow the glass primer to dry for approximately 10 minutes.
25. 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).
26. If using the extended method, cut the applicator nozzle in order to provide a bead of 12.7 mm (1/2 in) wide and 12.7 mm (1/2 in ) high.
27. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.
28. If reusing the original glass apply the new urethane adhesive on the top of the fresh trimmed urethane adhesive.
29. If installing a new glass (3) apply the urethane adhesive (2) to the freshly primed pinchweld flange.
If applying urethane adhesive to the inside edge of the windshield reveal molding (1) use the windshield reveal molding as a guide for the nozzle.
30. Use suction cups along with the aid of an assistant to install the windshield into the opening.
31. Place the windshield on the lower supports.
32. Align the tape lines on the windshield and the body (1).
33. Press the windshield firmly into place.
34. Tape the windshield to the body in order to minimize movement.
35. Clean any excess urethane adhesive from the body.
36. Use a soft spray in order to watertest the windshield immediately.
Using warm water is preferred in order to accelerate the curing of the urethane adhesive.
37. Do not direct a hard stream of high pressure water at the fresh applied urethane adhesive.
38. Inspect the windshield for leaks.
39. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
40. Retest the windshield for leaks.
CAUTION: At least 24 hours are required for complete curing of repair material. The repair area should not be physically disturbed until after that time. Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.
41. The following conditions must be maintained to properly cure the urethane.
1. Allow the vehicle to remain at room temperature (21 °C or 70 °F) at 30 percent relative humidity.
2. Allow a minimum of 6 hours for the moisture curing urethane adhesive.
3. Allow a minimum of 1 hour to 1 1/2 hours for the chemical curing urethane adhesive.
4. Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.
5. Do not drive the vehicle until the urethane adhesive is fully cured.
6. Do not use compressed air in order to dry the urethane adhesive.
42. Install the windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement.
43. Install the door sealing weatherstrip to the upper pinchweld flange.
44. Install the rear view mirror. Refer to Rearview Mirror Replacement.
45. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
46. Install the antenna, if equipped.Coaxial Cable Replacement in Entertainment.
47. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wiper/Washer System.
48. Remove the protective coverings and tape from the vehicle.