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Quarter Window Glass: Service and Repair




Quarter Window Replacement

Removal Procedure

Tools Required
* J 24402-A Glass Sealant Remover (Cold Knife)
* J 39032 Stationary Glass Removal Tool
* Isopropyl alcohol or an equivalent
* Cartridge-type caulking gun
* Commercial-type utility knife
* Razor blade scraper
* Suction cups
* Plastic Paddle

1. Remove the lower rear quarter trim panels from the vehicle. Refer to Rear Quarter Trim Panel Replacement (Rear Quarter Trim Panel Replacement) in Interior Trim.




2. Loosen the door opening lace.
3. Remove the quarter window interior trim.
4. Apply the masking tape to the area around the quarter window (1) in order to protect the painted surface from damage and to protect the headliner.
5. Cut the molding with a utility knife. Remove the reveal molding from the top and from the sides of the quarter window (1).





Caution: Refer to Glass and Sheet Metal Handling Caution in Cautions and Notices.

Important: Keep the cutting edge of the tool against the quarter window (1) when removing the quarter window. This will allow the urethane adhesive to be separated from the quarter window (1). Leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.


6. Use the J 24402-A or J 39032 in order to cut the quarter window (1) from the pinchweld flange. Do this from inside the vehicle in order to protect the outer paint surface.
7. Use the suction cups in order to lift the quarter window (1) and the quarter window reveal molding as an assembly from the opening.
8. Inspect the following components for the causes of a broken quarter window:

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

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

* High weld
* Solder spots
* Hardened spot weld sealer
* An obstruction or an irregularity in the pinchweld flange

Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are necessary, refinish the pinchweld flange in order to present a clean primer only surface. If paint repairs are required, mask the flange bonding area prior to the application of 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.


10. After repairing the opening as indicated, perform the following steps:
11. Inspect the condition of the quarter window opening and of the urethane adhesive bead in order to determine which installation method you will use. Refer to Short Method Description (Short Method Description) or Extended Method Description (Extended Method Description) for guidelines.

1. Remove all traces of broken glass from the vehicle.
2. 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.

Installation Procedure

Caution: Refer to Window Retention Caution in Cautions and Notices.

After repairing the opening as indicated, perform the following:




1. Shake the #3 black primer coating that is used on the pinchweld well.

Caution: Refer to Failure to Prep Primer Caution in Cautions and Notices.

2. Using a new dauber, apply the primer coating to the primed surface of the flange in the bond area.
3. Allow the primer coating to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.




4. If the original reveal molding is damaged it must be replaced.
Install the new reveal molding to the edge of the quarter window.
5. Fit the dry quarter window into the opening. Center the window in the window opening. Verify that the clearances are equal to the clearances that are shown in the figure.
6. Use masking tape in order to mark the location of the quarter window in the opening.
7. Slit the masking tape at the top edge of the quarter window.
8. With the aid of suction cups, remove the quarter window from the opening.
Place the quarter window inside up on a clean surface and on a protected surface.




9. If the original window is being reused, remove all but approximately 2 mm (3/64 in) of the existing urethane adhesive from the rear window surface, using a utility knife or razor blade scraper.
10. Clean around the edge of the inside surface of the quarter window (2) with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.





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


11. If the extended method is being used, remove all of the existing bead of urethane adhesive (1) except approximately 2 mm (3/64 in) from the pinchweld flange.
12. Shake the #3 black primer coating that is used on the pinchweld well.
13. Use a new dauber in order to apply the primer coating to the surface of the pinchweld flange.
14. Allow the primer coating to dry for approximately 10 minutes.
15. If the extended method is being performed, do the following:





Important: Use care when applying the prep (clear #1) to the quarter window. This primer dries almost instantly and may stain the viewing area of the quarter window if not applied evenly.


16. If you install a new quarter window that is not encapsulated, perform the following actions:

1. Use a new dauber, in order to apply the #3 clear window preparation to the area that is approximately 10 to 16 mm (3/8 to 5/8 in) around the entire perimeter of the quarter window inner surface.
2. Apply the #1 clear window preparation to the same area of the window.
3. Wipe the primed area immediately with a lint free cloth.
4. Shake the #2 black primer coating that is used on the pinchweld well.

17. If you install an new encapsulated window, perform the following actions:
Use a new dauber, in order to apply the #3 clear window preparation to the area approximately 10 to 16 mm (3/8 to 5/8 in) around the entire perimeter of the glass inner surface. The primer is good up to 8 hours after applying it to the glass.
18. The primed surface of the glass must be kept clean.
19. Allow the primer coating to dry for approximately 10 minutes.
20. Shake the rear window primer (black #2) for at least one minute.




21. Use a new dauber, in order to apply the rear window primer (black #2) to the areas of the rear window (1) to which prep (clear #1) was applied.
22. Allow the primer to dry for approximately 10 minutes.




23. 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).
24. 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.




25. Using a cartridge-type caulking gun, apply a smooth continuous bead of urethane adhesive around the edge of the window where the primer was applied.
26. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.
27. When using the extended method, apply a smooth, and continuous bead of urethane adhesive around the edge of the quarter window or the inside edge of the reveal molding where the primer coating was applied.




28. Using suction cups, install the quarter window into the opening.
29. Align the tape on the quarter window and on the body.
30. Press the quarter window firmly into position in order to wet-out and seat the urethane adhesive.
31. Tape the quarter window to the body in order to minimize movement until the urethane adhesive cures.
32. Clean excess urethane that has squeezed out from the body.





Important: Do not direct a hard stream of high pressure water at the fresh urethane adhesive.


33. Use a soft spray of warm water in order to immediately water test the quarter window.
34. Inspect the quarter window for leaks.
35. If you locate a leak, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
36. Retest the quarter window for leaks.
37. In order to correctly cure the urethane, observe the following rules:

* Allow the vehicle to remain at room temperature of 21°C (70°F) at 30 percent or less relative humidity.

Caution: Refer to Repair Material Curing Caution in Cautions and Notices.

* Allow the moisture curing urethane adhesive to cure for at least 6 hours.
* Allow the chemical curing urethane adhesive to cure for at least 1 to 1 1/2 hours.
* Partially lower a door window in order to prevent pressure buildups when closing doors prior to the curing of the urethane adhesive.
* Do not drive the vehicle until the urethane adhesive is completely cured. Refer to the above curing times.
* Do not use compressed air in order to dry the urethane adhesive.

38. Install the quarter window interior trim.
39. Install the lower rear quarter trim panels to the vehicle. Refer to Rear Quarter Trim Panel Replacement (Rear Quarter Trim Panel Replacement) in Interior Trim.
40. Install the lace of the door opening to the pinch weld flange.
41. Remove the protective coverings and tape from the vehicle and the headliner.

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