Windshield: Service and Repair

WINDSHIELD

OPERATION

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

The windshield is positioned in the reveal molding and is bonded to the windshield frame with urethane adhesive.
1. Cover the interior. and exterior body surface areas with a protective covering.
2. Remove the windshield wiper arms and the rearview mirror.
3. Using a razor knife, slide the blade between the windshield glass and the inboard edge of the reveal molding.
4. Cut around the interior perimeter of the reveal molding and sever the cap of the reveal molding.

Fig. 6:

5. Using a cold knife, cut the urethane around the perimeter of the windshield (Fig. 6).
6. Remove the windshield glass from the frame.

INSTALLATION - SHORT METHOD

The windshield is positioned in the reveal molding and is bonded to the windshield frame with urethane adhesive.

WARNING: REVIEW ALL WARNINGS AND CAUTIONS BEFORE PRECEDING WITH INSTALLATION.

1. Trim the urethane from the pinch weld flanges. Leave a 3 mm (0.1 in.) level base of urethane on the pinchweld flanges.

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

2. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
3. Prime outer perimeter of interior side of glass 16 mm (5/8 inch) from edge. Use a wipe-off type urethane primer and wipe glass dry after primer application.

NOTE: The reveal molding has an adhesive applied to the windshield contact surface to help secure the molding to the windshield during the installation procedure.

4. Apply the molding to the windshield:
- With the molding at room temperature, press the molding onto the windshield corners.
- From corner to corner, work the molding to the center of each side. (Some stretching of the molding may be required during this procedure.)

5. Place the glass on the pinchweld flanges and inspect for gaps in the urethane. Gaps in excess of 3 mm (1/8 inch) must be filled with urethane.
6. Adjust windshield glass position until it is aligned with the flanges and adhesive.
7. Using a grease pencil or equivalent, make alignment marks on the glass and body.
8. Remove replacement windshield from windshield opening.

Fig. 7:

9. 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. 7).

CAUTION: Avoid spilling or dripping primer on painted surfaces. Clean spills or drips immediately. The primer will damage the paint if it remains on the surface for any length of time.

10. If the replacement windshield glass does not have blackout primer:

Fig. 8:

- Attach a 25 mm (1 in) wide masking tape band around the interior side of the glass 16 mm (5/8 in) from the edge of the glass (Fig. 8).
- Do not attach tape along the bottom of the glass and attach it only to the inside of the glass.
- Clean the 16mm (5/8 in) wide surface area around the glass with isopropyl alcohol.

Fig. 9:

- Thoroughly mix and apply glass blackout primer to the 16 mm (5/8 in) surface area around the interior side of the glass (Fig. 9).
- Allow the primer to dry for at least 10-12 minutes.

Fig. 10:

11. Apply a small amount of adhesive to the bottom support spacers and attach the support spacers to the bottom of the windshield, 170 mm inboard from the outer windshield edge (Fig. 10).

Fig. 11:

12. Cut the urethane adhesive applicator nozzle (Fig. 11).

CAUTION: Be prepared to install the glass immediately after applying the adhesive, as the adhesive will begin to cure in less than 10 minutes.

13. Apply a continuous, 6 mm (1/4 in) diameter bead of urethane adhesive to the surface area.
14. Align the glass with the reference marks and position the glass on the pinchweld flanges. Ensure that the windshield glass is correctly seated on the support spacers.
15. Force the windshield glass inward just enough to wet-out and set the urethane. Use care to avoid excessive squeeze-out of adhesive.
16. Water test the windshield with a water spray after installation. Do not direct high pressure streams of water directly at urethane. If any leaks are detected, apply urethane as necessary.
17. If used, remove the masking tape from the inner surface of the glass.
18. Install all components and clean the vehicle.
19. Open the vehicle windows to prevent interior pressure while the urethane is curing.If not vented, pressure in the interior of the vehicle may interfere with proper glass bonding.
20. Install the rearview mirror.