Cowl: Service and Repair

Windshield Panel Replacement - Lower

Removal Procedure

Caution: Refer toApproved Equipment for Collision Repair Caution in Cautions and Notices.
1. Disable the SIR system. Refer toSIR Disabling and Enabling Zones in SIR.
2. Disconnect the negative battery cable. Refer toBattery Negative Cable Disconnect/Connect Procedure in Engine Electrical.




3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications.
Caution: Refer toFoam Sound Deadeners Caution in Cautions and Notices.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer toAnti-Corrosion Treatment and Repair () in Paint and Coatings.





Important: Do not damage any inner panels or reinforcements.


6. Locate and drill out all factory welds. Note the number and location of welds for installation of the windshield frame side panel.




7. Using a grinder or an equivalent tool, remove the silicon bronze welds at the upper windshield frame side panel and header location.




8. Remove the damaged windshield frame side panel.



Installation Procedure





1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary at the locations noted from the original windshield frame side panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M(R) Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.




4. Position the windshield frame side panel.




5. Plug weld accordingly.
6. Continuous weld the upper windshield frame side panel to the header joint.
7. Clean and prepare all welded surfaces.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer toAnti-Corrosion Treatment and Repair () in Paint and Coatings.
9. Paint the repair area. Refer toBasecoat/Clearcoat Paint Systems (Basecoat/Clearcoat Paint Systems) in Paint and Coatings.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer toBattery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
12. Enable the SIR system. Refer toSIR Disabling and Enabling Zones in SIR.