Windshield: Service and Repair

WINDSHIELD

REMOVAL

1. Remove inside rear view mirror.
2. Remove cowl cover.
3. Remove screws attaching windshield side molding to A-pillar.
4. Cut urethane bonding from around windshield using a suitable sharp cold knife. A pneumatic cutting device can be used if available.
5. Separate windshield from vehicle.

INSTALLATION

WARNING: Review all warnings and cautions before preceding with installation.

CAUTION: Open a window before installing windshield. This will avoid pressurizing the passenger compartment. If a door or swing gate flip-up glass is slammed before urethane is cured, water leaks can result.

The windshield fence should be cleaned of old urethane bonding material. Support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening.
1. Place replacement windshield into windshield opening. Position glass in the center of the opening against the support spacers. Mark the glass at the support spacers with a grease pencil or masking tape and ink pen to use as a reference for installation. Remove replacement windshield from windshield opening.
2. 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.
3. Clean inside of windshield with Mopar(R) Glass Cleaner and lint-free cloth.
4. Apply clear glass primer 25 mm (1 in.) wide around edge of windshield. Wipe with clean/dry lint-free cloth.
5. Apply black-out primer 15 mm (0.75 in.) wide on top and sides of windshield and 25 mm (1 in.) on bottom of windshield. Allow at least three minutes drying time.
6. Position windshield spacers on lower fence above support spacers at the edge of the windshield opening.
7. Align the dot on the upper molding to the tick mark in the center of the glass and install upper molding onto windshield.
8. Apply a 10 mm (0.4 in.) bead of urethane around perimeter of windshield along the inside of the moldings. Apply two beads along the bottom edge.
9. Apply fence primer around the perimeter of the windshield opening fence. Allow at least 18 minutes drying time.
10. With aid of a helper, position windshield over windshield opening. Align reference marks at bottom of windshield to support spacers.
11. Slowly lower windshield glass to windshield opening fence. Guide top molding into proper position if necessary. Push windshield inward to fence spacers at bottom and until top molding is flush to roof line.
12. Clean excess urethane from exterior with Mopar(R) Super Clean or equivalent.
13. Install windshield side moldings.
14. Install cowl grille.
15. Install inside rear view mirror.
16. After urethane has cured, water test windshield to verify repair.