Repair Procedures A and B
REPAIR PROCEDURE A
1. Cut two, 150 mm x 5 mm pieces of EPT Sealer 5T.
2. Cut the ends of each piece into a 3 mm point.
3. At the upper corners of the windshield, clean the inside lip of the molding.
^ Lift out the molding lip with a seal pick.
^ Clean the inside area of the lip with an alcohol wipe. Allow the area to air dry.
4. Remove the backing from one of the EPT pieces. Then center the EPT around the corner of the windshield, and stuff it inside the molding lip with a plastic card.
5. Press the molding lip back into place with the plastic card.
6. Check the corner fit of the molding.
^ If the molding presses against the sheet metal, do steps 3 thru 6 on the other side, then go to step 8.
^ If the molding does not press against the sheet metal, go to step 7.
7. Remove the EPT, then repeat steps 1 thru 6 using a 150 mm x 10 mm piece of EPT.
8. Test-drive the vehicle to make sure the wind noise is gone.
^ If the noise is gone, return the vehicle to the customer.
^ If you still hear the noise, go to REPAIR PROCEDURE B.
REPAIR PROCEDURE B
NOTE:
Windshield removal and installation can be done by a qualified glass installer, but you must do steps 1 thru 13 to prepare the windshield for installation, and steps 15 thru 19 to fit the windshield to the body.
1. Make sure the temperature of the vehicle and all parts is above 65 degrees F. This is especially important for the windshield molding.
2. Carefully unpack the windshield, then clean both sides with glass cleaner, and place it on a glass stand, inside facing up.
3. Using alcohol wipes, clean the edge of the windshield and 20 mm inward from the edge, inside and out. Allow the windshield to air dry.
NOTE:
If you touch or contaminate the cleaned area, clean it again before installing parts.
4. Attach the four-piece dam set to the windshield:
NOTE:
The longest dam goes along the top, the next longest goes on the bottom, and the two, equal length pieces go on either side.
^ Starting with the top dam, peel back about 50 mm of its brown backing paper.
^ Near either top corner of the windshield, locate the 5th mark from the corner. This is the starting point for the dam.
^ At the starting point, use a steel ruler to measure 1/2-inch (12 mm) inward from the edge of the glass.
^ Apply the first 50 mm of the dam, sliding the ruler along to maintain the 1/2-inch space from the edge. Do not stretch the dam.
^ Peel back another 2-inches of backing paper, and apply that part of the dam to the glass, using the ruler to maintain your 1/2-inch distance from the edge. Continue applying the dam in 2-inch segments until you reach its end.
^ Make sure the end of the dam goes to the 5th mark on the opposite side of the windshield. If needed, cut off any excess dam with a razor knife.
^ Install the side dams the same way, starting at the 3rd mark from the corner at the top of the windshield, and ending at the 3rd mark from the bottom on the side of the windshield.
^ Install the bottom dam the same way, starting and ending the dam at the lowest marks on the sides of the windshield.
5. Install the glass fasteners to the left and right sides of the windshield:
^ Using a urethane primer dauber, apply urethane primer in two places on the top of the windshield, between the dams and the locating marks. Allow the primer to dry.
^ Remove the adhesive protector from the fasteners.
^ Using the ruler, measure 1/2-inch (12 mm) inward from the edge of the glass, then apply the fasteners between the locating marks. Press each fastener to set its adhesive.
6. Again, use alcohol wipes to clean the edge of the windshield and 20 mm inward from the edge, inside and out. Allow the windshield to air dry.
NOTE:
If you touch or contaminate the cleaned area, clean it again before installing any more parts.
7. Apply urethane primer to the top and sides of the windshield:
^ Using a urethane primer dauber, apply the primer to the top of the windshield, between the marks, in two areas. Allow the primer to dry.
^ Apply the primer to each side of the windshield, between the marks. Allow the primer to dry.
8. Install the windshield molding:
NOTE:
During installation keep the groove in the molding square along the edge of the windshield, and do not stretch the molding. Molding that is stretched or not square will cause a wind noise.
^ Locate the center mark on the molding.
^ Remove the adhesive protector from the molding.
^ Line up the center mark on the molding with the center mark at the top of the windshield. Make sure the molding mark faces inward and the lip of the molding faces outward.
^ At the marks, begin installing the molding by pressing its groove squarely onto the edge of the windshield. Move toward the corner of the windshield, inch by inch, keeping the groove square on the edge.
^ As you press the molding onto the windshield, push it back toward the center marks. This helps to avoid stretching it.
^ When you get near a corner, push the top of the molding back tightly as you press it into place on the glass.
^ Press and pinch the entire edge of the molding to activate its adhesive.
9. Using alcohol wipes, clean the molding where the felt and foam blocks will be installed.
10. Attach the upper foam pieces to the molding:
^ Remove the adhesive protector from an upper foam piece.
^ Attach the foam lengthwise, across the molding, between the marks on the windshield.
^ Attach the opposite side foam the same way.
11. Attach the felt pieces to the molding:
^ Separate the felt into two pieces.
^ Remove the adhesive protector.
^ Starting at the end of an upper foam piece, attach the felt to the windshield, around the corner using a twist-and-press motion.
^ Attach the opposite side felt the same way.
12. Attach the side foam pieces to the molding:
^ Remove the adhesive protector from a side foam piece.
^ Attach the foam near the end of the molding, between the marks.
^ Attach the opposite side foam the same way.
13. Install EPT Sealer 5T in the corners of the molding:
^ Cut two 150 mm x 5 mm pieces of EPT Sealer 5T.
^ Cut the end of each piece into a 3 mm point.
^ Roll the molding lip up at the upper corners of the windshield, then clean the inside of the molding lip with an alcohol wipe, and let it dry.
^ Remove the backing from one of the EPT strips. Then center the strip around the corner of the molding, and stuff it inside the molding lip with a plastic card.
^ Use the card to press the molding lip back into place.
14. Remove the original windshield:
^ See the 2006 Ridgeline Service Manual, pages 20-31 and 20-32, steps 1 thru 11, or
^ Online, enter keyword WINDSHIELD, and select Windshield Replacement from the list.
15. Do a dry fit of the windshield without adhesive:
^ With the help of an assistant, carefully insert the windshield into its opening, then hold its molding to the roof with 2-inch-wide masking tape.
^ Check the tension on both sides of the windshield molding, where the roof and the A-pillar intersect, by sliding a business card between the lip of the molding and the sheet metal.
- If the lip of the molding is pressed against the sheet metal with no gap, go to step 16.
- If the lip of the molding does not press against the sheet metal, remove the windshield, and repeat step 13 with a 150 mm X 10 mm piece of EPT Sealer 5T.
16. Carefully remove the windshield, and place it on the glass stand.
17. Attach the body fasteners to the body:
^ Using a urethane primer dauber, apply urethane in two places at the top of the windshield opening, between the locating dimples in the sheet metal. Allow the primer to dry.
^ Remove the adhesive protectors from the fasteners.
^ Apply the fasteners between the dimples. Press each fastener to set its adhesive.
18. Install the new windshield:
^ See pages 20-34 and 20-35 of the service manual, steps 19 thru 26, or
^ Online, enter keyword WINDSHIELD, and select Windshield Replacement from the list.
19. Press the windshield upward, and hold its molding against the roof with two pieces of 2-inch wide masking tape. Apply the tape 2 inches to the left and right of the windshield centerline.
20. Center the windshield, side-to-side, by pushing the glass left or right until the side moldings are at equal distances from the A-pillars.
21. Adjust the top and side windshield molding height:
NOTE:
To avoid air pockets and voids in the windshield adhesive, never push out the windshield glass from the inside.
^ Lay a plastic card across the top center of the windshield, where the roof meets the molding.
^ If needed, push in the glass to make the molding flush with the roof.
^ Move the card toward the left and the right roof molding, checking the molding height. If needed, push in the molding to make it flush with the roof.
^ Check the side moldings the same way as the top molding. Unlike the top molding, the side moldings will be slightly higher than the A-pillars.