Backlight Glass
Backlight Glass
Service Repair No - 76.81.10
NOTE: The following equipment is required:
Masking tape.
Sharp knife.
Cutting wire and handles, or a reciprocating blade, powered cutting knife*,
Suction lifters.
Windscreen repair kit.
Sealer applicator gun.
* A reciprocating blade cutting tool, such as 'FEIN Special Cutter' is recommended for this operation. A flat blade, with an effective length of at least 25 mm and a 'U' shaped blade of at least 30 mm are required.
WARNING: Wear protective gloves when handling glass, solvents and primers.
Remove
1. Remove interior trim from tailgate.
2. Release backlight lower finisher from 7 clips.
3. Remove backlight lower finisher.
4. Remove backlight side finishers.
NOTE: Side finishers are secured to backlight with P.U. sealer. New backlight glasses are supplied with side finishers fitted. Side finishers are available separatley if original glass is to be refitted.
5. Remove rubber finisher from upper edge of backlight glass.
6. Protect tailgate panel with masking tape.
7. Disconnect two Lucar terminals from screen heater element.
Removal Using Reciprocating Blade Tool
8. Cut through P.U. adhesive along sides of screen using flat blade.
9. Using a 'U' shaped blade, cut through adhesive bead along upper and lower edges of glass.
CAUTION: Access around lower clips is restricted. Manoeuvre blade to cut through as much adhesive as possible.
10. Attach suction lifters to glass. With assistance, cut through remaining sealant around lower clips.
11. With assistance, remove backlight glass.
Removal Using Cutting Wire Handles
12. Using a sharp knife, cut through P.U. sealer at side of backlight.
13. Insert cutting wire through knife cut and fit handles, as shown, with approximatley 200 mm of wire between handles.
14. With assistance, wedge tube of handle 'A' between glass and body, ahead of the cutting position, and carefully cut the sealer using a continuous pull on handle 'B' from the outside. Cut side and top edges first. Attach suction lifters and restrain glass as last of sealant is cut.
NOTE: When cutting along lower edge, manoeuvre wire between glass edge and finisher clips to reduce strain on wire.
15. With assistance, remove backlight glass.
Refit
16. Carefully cut old sealer from body flange to obtain a smooth surface, approximately 2 mm thick.
CAUTION: Do not cut down to painted surface.
17. Renew broken finisher clips as necessary. Position finisher clips centrally on tailgate studs.
NOTE: Clips control height and seating of lower glass edge.
18. Position and centralize new backlight to tailgate. Apply tape reference mark to aid final fitment.
19. Position new backlight on felt covered surface.
20. Fit and centralize rubber finisher to top of glass.
NOTE: Finisher controls seating depth of glass top edge.
21. Apply cleaning solvent to sealing surface of glass and body flange.
CAUTION: Do not touch cleaned or primed areas with fingers.
22. Shake primer tins for at least 30 seconds. Apply body primer to sealing surface of body flange using supplied applicator.
23. Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for each primer.
24. Remove lid from sealer cartridge, remove crystals, pierce membrane and fit pre-cut nozzle. Fit cartridge to applicator gun.
NOTE: The profile of the nozzle must be modified slightly to produce the required bead section.
25. Apply a continuous bead of sealer to backlight as shown.
26. Original glass: Apply 3 mm bead of sealer to channels of side finishers and fit to backlight.
27. Fit suction lifters to glass.
28. With assistance, fit glass and centralize to previously made tape markings. Set glass to correct depth.
29. Connect screen heater.
30. Remove reference and protective tapes.
31. Position lower finisher and secure to clips.
32. Fit interior trim to tailgate.
CAUTION: A curing time of 6 hours is recommended. During this time, leave the windows open and DO NOT slam the doors.