Windshield: Service and Repair

WINDSHIELD

REMOVAL

The windshield is positioned in the reveal molding and is bonded to the windshield frame with urethane adhesive. The windshield interior trim molding is positioned onto the inner windshield frame pinchweld.

1. Cover body surface areas with protective covering to avoid paint damage and extra clean-up time.
2. Remove the windshield wiper arms.
3. Remove the rear view mirror.
4. Using a razor knife, slide the blade between the windshield glass and the inboard edge of the reveal molding.
5. Cut around the interior perimeter of the reveal molding and sever the cap of the reveal molding.
6. Using a cold knife, cut the urethane around the perimeter of the windshield.

Fig. 2:

7. Remove the windshield glass from the frame (Fig. 2).

INSTALLATION

1. Trim the urethane from the pinchweld flanges. Leave a 3 mm (0.1 in.) level base of urethane on the pinchweld flanges.
2. Place replacement windshield into windshield opening and position glass in the center of the opening against pinchweld flange.
3. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinchweld flange must be formed to the shape of the new glass. Next, make alignment marks on glass and body with a grease pencil.
4. Remove replacement windshield from windshield opening.

Fig. 3:

5. 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. 3).

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

6. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
7. Apply molding to perimeter of windshield. The butt weld of the molding should be centered at the bottom edge of the windshield.
8. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible.
9. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time.
10. Apply Pinchweld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time.

Fig. 4:

11. Apply a urethane bead (Fig. 4) on the pinchweld flange surface area 6 mm (.25 in.) from the outboard edge.

CAUTION: Be prepared to install the windshield glass immediately after applying the adhesive. The adhesive begins to cure within 10-15 minutes.

12. Align the windshield with the grease pencil marks and position windshield on pinchweld flanges.
13. Push the windshield glass inward until the reveal molding is seated on the windshield frame. Use care to avoid excessive squeeze-out of adhesive.
14. Open windows and liftgate to prevent pressure build-up while the urethane is curing.
15. Starting in each corner, apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold windshield in place until urethane cures.
16. Install the rear view mirror support bracket.
17. Install the rear view mirror.
18. Install the wiper arms.
19. After urethane has cured, remove tape strips and water test windshield to verify repair.