Windshield Replacement
Windshield Replacement
Tools Required
* J 24402-A Glass Sealant (Cold Knife) Remover
* J 39032 Stationary Glass Removal Tool
* Isopropyl alcohol or Equivalent
* Cartridge-type Caulking Gun
* Commercial-type Utility Knife
* Razor Blade Scraper
* Suction Cups
* Plastic Paddle
Removal Procedure
Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and inner trim of the window.
1. Open the hood.
2. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement.
3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement (Service and Repair) in Body Front End.
4. Remove the rain sensor. Refer to Windshield Outside Moisture Sensor Replacement.
5. Remove the rearview mirror. Refer to Inside Rearview Mirror Replacement (Spring Clip Mount) (Inside Rearview Mirror Replacement (Spring Clip Mount))Inside Rearview Mirror Replacement (Set Screw Mount) (Inside Rearview Mirror Replacement (Set Screw Mount)) .
6. Remove the instrument panel upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement (Service and Repair) in Instrument Panel, Gages and Console.
7. Remove the windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement (Windshield Side Reveal Molding Replacement) .
Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.
8. Cover the defroster openings.
Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.
9. Use safety glasses and gloves.
Important: The windshield reveal molding fills the cavity between the body and the windshield.
The reveal moldings must be replaced if stretched or damaged.
10. Using a sharp utility knife, make a preliminary cut around the perimeter of the windshield. Cut as close to the edge of the windshield as possible.
11. Remove the lower windshield supports (1) from the cowl panel if equipped.
Important: Keep the cutting edge of the tool against the windshield. This will allow the urethane adhesive to be separated from the windshield and leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.
12. Use the J 24402-A or J 39032 in order to remove the windshield.
13. Push out on the upper portion of the windshield and insert wooden blocks between the windshield and the front body hinge pillars.
14. From the inside of the vehicle, using a sharp utility knife, cut the lower urethane adhesive bead from the pinchweld flange.
15. With the aid of an assistant, use suctions cups to lift the windshield from the opening.
16. Remove the windshield from the vehicle.
Installation Procedure
1. Verify all primers and urethane adhesive are within expiration dates.
Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392 (Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.
2. Inspect the following components for the causes of a broken windshield:
* The flange of the windshield opening
* The windshield reveal molding
3. Inspect for any of the following problems in order to help prevent future breakage of the windshield:
* High weld
* Solder spots
* Hardened spot weld sealer
* Any other obstruction or irregularity in the pinchweld flange.
Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are required, the pinchweld flange must be refinished in order to restore the bonding area strength. If paint repairs are required, mask the flange bonding area prior to applying 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.
4. After repairing the opening as indicated, perform the following steps:
1. Inspect the condition of the windshield opening and the adhesive bead to determine which installation method should be used. Refer to Short Method Description (Short Method Description) or Extended Method Description (Extended Method Description) for the guidelines.
2. Remove no more of the urethane adhesive from the pinchweld than necessary in order to maintain the original shape. This will ensure the proper clearance between the windshield and the pinchweld flange.
3. Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.
4. Clean around the edge of the inside surface of the windshield with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.
5. After repairing the opening as indicated, shake the pinchweld primer (black #3) for at least one minute.
Caution: Failure to prep the area prior to the application of primer may cause insufficient bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.
6. Use a new dauber to apply the pinchweld primer (black #3) to the surface (1) of the bonding area on the body only.
7. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.
8. Install the lower windshield supports (1) to the cowl panel, if equipped.
9. Install a new acoustic strip, if necessary.
10. Install a new windshield upper reveal molding. Refer to Windshield Upper Reveal Molding Replacement (Windshield Upper Reveal Molding Replacement) .
11. With the aid of an assistant, dry fit the windshield in the opening in order to determine the correct position.
12. Use masking tape (1, 2) in order to mark the location of the windshield in the opening.
13. Slit the masking tape at the edge of the windshield.
14. With the aid of an assistant and the suction cups, remove the windshield from the opening.
15. Place the windshield inside up on a clean, protected surface.
Important: Do not remove all traces of the adhesive. Remove all mounds or loose pieces of urethane adhesive.
16. If the original windshield is to be reused, remove all but a thin film of the existing urethane adhesive from the windshield surface by using a utility knife or razor blade scraper.
17. If the extended method is being used, remove all but approximately 2 mm (5/64 in) of the existing bead of adhesive from the pinchweld flange.
18. Clean the inside surface of the windshield with a 50/50 mixture of isopropyl alcohol and water, with a lint free cloth.
Important: Do not apply the (black #3) primer to the existing bead of the urethane adhesive. Apply the primer only to nicks, scratches or the primed surfaces.
19. Shake the pinchweld primer (black #3) for at least one minute.
20. Use a new dauber to apply the primer to the surface of the pinchweld flange.
21. Allow the pinchweld primer to dry for approximately 10 minutes.
Important: Use care when applying the glass prep (clear #1) to the windshield. This primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly.
22. Use a new dauber in order to apply glass prep (clear #3) to an area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the window inner surface.
23. Apply a second coat of the glass prep (clear #1) to the same area of the glass.
24. Wipe the glass primed area immediately with a clean lint free cloth.
25. Shake the glass primer (black #2) for at least one minute.
26. Use a new dauber in order to apply the glass primer (black #2) to the same areas (2) that the glass prep (clear #1) was applied.
The glass primer (black #2) is good up to 8 hours after applying it to the glass (1). The primed surface of the glass must be kept clean.
27. Allow the glass primer to dry for approximately 10 minutes.
28. Cut the tip of the applicator nozzle as follows:
1. 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).
2. If using the extended method, cut the tip of applicator nozzle in order to provide a bead of 12.7 mm (1/2 in) wide and 12.7 mm (1/2 in) high.
29. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.
30. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive to the body.
31. When using the extended method, use the edge of the windshield, or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (1) to the inner surface of the windshield (3).
If applying urethane adhesive to the inside edge of the windshield reveal molding (2), use the windshield reveal molding as a guide for the nozzle.
32. Place the windshield on the lower supports.
33. With the aid of an assistant, use suction cups in order to install the windshield in the opening.
34. Align the tape on the windshield and the body (1, 2).
35. Press the windshield firmly into place.
36. Tape the windshield to the body in order to minimize movement, until the urethane adhesive cures.
37. Clean any excess urethane adhesive from the body.
Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.
38. Use a soft spray of water in order to watertest the windshield immediately.
39. Inspect the windshield for leaks.
40. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
41. Retest the windshield for leaks.
Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.
* For the moisture-curing type of urethane adhesive, allow a minimum of 6 hours at 21°C (70°F) or greater and with at least 30 percent relative humidity. Allow at least 24 hours for the complete curing of the urethane adhesive.
* For the chemical-curing type of urethane adhesive, allow a minimum of 1 hour .
Do NOT physically disturb the repair area until after these minimum times have elapsed.
42. The following conditions must be maintained to properly cure the urethane.
* Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.
* Do not drive the vehicle until the urethane adhesive is cured.
* Do not use compressed air in order to dry the urethane adhesive.
43. Remove the protective covering from the defroster ducts.
44. Install the instrument panel upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement (Service and Repair) in Instrument Panel, Gauges and Console.
45. Install the rearview mirror. Refer to Inside Rearview Mirror Replacement (Spring Clip Mount) (Inside Rearview Mirror Replacement (Spring Clip Mount))Inside Rearview Mirror Replacement (Set Screw Mount) (Inside Rearview Mirror Replacement (Set Screw Mount)) .
46. Install the rain sensor. Refer to Windshield Outside Moisture Sensor Replacement.
47. Install the windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement (Windshield Side Reveal Molding Replacement) .
48. Install the door sealing weather strip.
49. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement (Service and Repair) in Body Front End.
50. Install the windshield wipers arms. Refer to Windshield Wiper Arm Replacement.
51. Remove the protective tape from the painted surfaces and headliner.
52. Close the hood.