Windshield: Service and Repair

WINDSHIELD

REMOVAL

1. Remove inside rear view mirror.
2. Remove cowl grille.
3. Remove windshield moldings. Pull outward on molding at the bottom of A-pillars using pliers.

Fig. 1:

4. Cut urethane bonding from around windshield using a suitable sharp cold knife. A pneumatic cutting device can be used if available (Fig. 1).
5. Separate windshield from vehicle.

INSTALLATION

CAUTION: Open a window before installing the windshield. This will prevent the pressurizing of the passenger compartment after the windshield is installed. If a door or the trunk lid is slammed before the urethane is cured around the windshield, water leaks may result.

Allow the urethane a minimum of 4 hours to cure before returning the vehicle to use.

1. Trim the urethane from the pinchweld flanges. Leave a 3 mm (0.1 in.) level base of urethane on the pinchweld flanges. Support spacers should be cleaned and properly installed on weld studs or repair screws at the bottom of the windshield opening.

Fig. 2:

2. Position the windshield molding and position the replacement windshield in the windshield opening. Center the glass in 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 (Fig. 2). Remove the replacement windshield from the opening.

Fig. 3:

3. 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.

4. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
5. Apply molding to perimeter of windshield.
6. 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.
7. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time.
8. Apply Pinchweld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time.

Fig. 4:

9. Position windshield spacers on lower fence above support spacers at the edge of the windshield opening (Fig. 4).
10. Apply a 10 mm (0.4 in.) diameter bead of urethane 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 to 15 minutes.

11. With aid of a helper, position windshield over windshield opening. Align reference marks at bottom of windshield to support spacers.
12. 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.
13. Clean excess urethane from exterior with Mopar, Super Clean or equivalent.
14. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures.
15. Install cowl grille.
16. Install inside rear view mirror support bracket.
17. After urethane has cured, remove tape strips. Water test windshield to verify repair.