Window Glass - Rear
Window Glass - Rear
Removal
NOTE: If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the existing rear window glass.
Regular and Crew Cab vehicles
1. Remove the rear trim panel.
SuperCab vehicles
2. Remove the rear seat backrest. For additional information, refer to Seats.
3. Remove the rear center safety belt retractor. For additional information, refer to Restraint Systems.
4. Remove the B-pillar trim panels.
Crew Cab vehicles
5. If equipped, remove the rear DVD system. For additional information, refer to Accessories and Optional Equipment.
6. Remove the RH and LH rear assist handles.
All vehicles
7. Remove the RH and LH rear garment hooks.
8. If equipped, remove the roof opening panel trim.
Crew Cab and SuperCab vehicles
9. Remove the 3 rear headliner pushpin retainers.
All vehicles
10. Lower the rear of the headliner.
Vehicles with power sliding window
11. Position the sliding glass to the halfway OPEN position.
12. Remove the bumpers from the sliding window bracket.
13. NOTICE: Slowly release the spring tension after the cable swag is removed from the sliding glass channel bracket. If the spring tension is suddenly released, the cables can unwind from the drum. If the cables unwind from the drum, a new regulator and motor assembly will have to be installed.
NOTE: RH shown, LH similar.
Remove the cable swags from the sliding window glass channel bracket.
- Carefully squeeze the regulator and motor assembly spring to create slack in the cable.
- Remove the cable swag from the sliding window glass channel bracket.
14. Pull the LH and RH cable ends out of the sliding window trough.
All vehicles
15. NOTE: Refer to the manufacturer's instructions before using the Deluxe Windshield Removal Tool.
Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting the urethane adhesive.
16. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinch weld during glass removal.
NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement rear glass.
NOTE: Support the rear glass as necessary to prevent the glass from dropping while cutting the urethane adhesive.
Using the Deluxe Windshield Removal Tool, cut at the upper center of the rear glass and work toward the bottom corners. Then cut through the remaining urethane adhesive along the bottom of the rear glass.
17. NOTE: Removal of the rear window glass requires an assistant to hold the rear window glass as it is pushed out.
Release the upper and lower retaining clips and remove the rear window glass from the vehicle.
Installation
All vehicles
1. NOTE: It is important that the rear glass has a bottom margin of 5 mm (0.19 in).
Dry-fit the new rear glass on the existing urethane adhesive bead on the pinch weld.
- Position the rear glass on the pinch weld. The bottom of the glass should have a 5 mm (0.19 in) margin from the bottom of the pinch weld area.
- Center the rear glass in the opening.
- Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body.
2. After the dry-fit alignment, remove the glass assembly from the opening and place on a stable work surface with the interior side of the glass facing up.
3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following the manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinch weld.
4. If reinstalling the original rear glass, remove any excess urethane adhesive from the glass.
5. If installing a new rear glass, clean the inside of the glass surface with glass cleaner.
6. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. For additional information, refer to the Material Chart in this procedure.
If installing a new rear glass, apply urethane glass primer according to the manufacturer's instructions. Allow at least 6 minutes to dry.
7. Cut the urethane adhesive applicator tip to specification.
8. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that applies the urethane adhesive with less effort and a continuous bead.
Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld starting and ending at the bottom of the rear glass near the center, making sure there are no gaps in the bead.
9. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the rear glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.
Using the alignment marks, install the rear glass.
10. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
After the urethane adhesive cures, check the rear glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
Vehicles with power sliding window
11. Position the sliding glass to the halfway OPEN position.
12. Install the LH and RH cable ends into the sliding window trough.
13. NOTICE: Slowly release the spring tension after the cable swag is installed into the sliding glass channel bracket. If the spring tension is suddenly released, the cables can unwind from the drum. If the cables unwind from the drum, a new regulator and motor assembly will have to be installed.
NOTE: RH shown, LH similar.
Install the cable swags into the sliding window glass channel bracket.
- Carefully squeeze the regulator and motor assembly spring to create slack in the cable.
- Install the cable swag into the sliding window glass channel bracket.
14. Install the bumpers into the sliding window bracket.
Crew Cab and SuperCab vehicles
15. Install the 3 rear headliner pushpin retainers.
All vehicles
16. If equipped, install the roof opening panel trim.
17. Install the RH and LH rear garment hooks.
Crew Cab vehicles
18. Install the RH and LH rear assist handles.
19. If equipped, install the rear DVD system. For additional information, refer to Accessories and Optional Equipment.
SuperCab vehicles
20. Install the B-pillar trim panels.
21. Install the rear center safety belt retractor. For additional information, refer to Restraint Systems.
22. Install the rear seat backrest. For additional information, refer to Seats.
Regular and Crew Cab vehicles
23. Install the rear trim panel.