Window Glass - Roof
Window Glass - Roof
NOTE: A new replacement glass panel must be installed whenever a glass panel has been removed.
Removal
Front or rear glass panel
1. Remove the headliner. For additional information, refer to Interior Trim and Ornamentation Service and Repair.
Front glass panel
2. Remove the LH and RH front sunshade tracks. For additional information, refer to Interior Trim and Ornamentation Sunshade Track.
Rear glass panel
3. Remove the sunshade motor and both LH and RH rear sunshade tracks. For additional information, refer to Interior Trim and Ornamentation Sunshade Motor.
Front or rear glass panel
4. NOTE: Refer to manufacturer's instructions before using the Deluxe Windshield Removal Tool.
NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass.
Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting the urethane adhesive.
5. 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.
NOTE: There is a locator pin in the RH front corner (front glass panel only) and LH rear corner (rear glass panel only) which may cause resistance during removal. When all the urethane adhesive has been cut for the trim ring, the corner tab where the locator pin is attached will need to be cut before the trim ring can be completely removed.
Remove and discard the plastic trim ring from the glass panel.
- Using the Deluxe Windshield Removal Tool, begin cutting the urethane adhesive from the inside of the vehicle starting at the front center, working toward the front corners.
- Continue working through the remaining urethane adhesive toward the rear corners.
- Remove and discard the plastic trim ring.
Front glass panel
6. NOTICE: Be careful with the cutting depth while cutting the urethane adhesive bead on the trailing edge of the front glass panel. If the cutting tool is inserted too far, it may cut into the urethane adhesive bead on the leading edge of the rear glass panel, which may cause a water leak.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or otherwise damage the pinch weld during removal.
From inside the vehicle, use the Deluxe Windshield Removal Tool to cut the glass panel urethane adhesive.
- Begin cutting at the center of the trailing edge of the glass panel, working toward the rear corners.
- Continue cutting toward the front corners.
- Cut the side weatherstrips in the center of where the front and rear glass panels meet. This will allow the replacement glass panel weatherstrip to be fitted correctly to the remaining weatherstrip.
- Using The Pumper (or an assistant) to raise the glass slightly, continue cutting the remaining urethane adhesive along the leading edge of the glass panel.
- Remove the glass panel from the vehicle.
Rear glass panel
7. NOTICE: Be careful with the cutting depth while cutting the urethane adhesive bead on the leading edge of the rear glass panel. If the cutting tool is inserted too far, it may cut into the urethane adhesive bead on the trailing edge of the front glass panel, which may cause a water leak.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or otherwise damage the pinch weld during removal.
From inside the vehicle, use the Deluxe Windshield Removal Tool to cut the glass panel urethane adhesive.
- Begin cutting at the center of the leading edge of the glass panel, working toward the front corners.
- Continue cutting toward the rear corners.
- Cut the side weatherstrips in the center of where the front and rear glass panels meet. This will allow the replacement glass panel weatherstrip to be fitted correctly to the remaining weatherstrip.
- Using The Pumper (or an assistant) to raise the glass slightly, continue cutting the remaining urethane adhesive along the trailing edge of the glass panel.
- Remove the glass panel from the vehicle.
Installation
NOTICE: The replacement glass panel(s) are factory-primed. If the replacement glass panel is not installed within 90 days of shipment, obtain Dow Betaseal 43533ATU commercially and apply primer according to manufacturer's instructions before installation.
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. Refer to the Material Chart in this procedure.
Front or rear glass panel
NOTE: All appropriate weatherstrip seals are part of the new glass panel assembly. The glass panel will be factory primed with a shelf-life of 90 days.
1. Dry fit the roof glass panel to the existing urethane adhesive bead on the body pinch weld. Align the roof glass panel in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks on the roof glass panel and the body to aid in the installation alignment of the roof glass panel.
3. Remove the roof glass panel and place on a stable surface.
4. 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: To make sure the new urethane adhesive bonds correctly to the original equipment urethane adhesive, the roof glass panel must be installed within 2 hours of trimming the original urethane adhesive bead.
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following 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 1-2 mm (0.04-0.08 in) base of original equipment urethane adhesive on the pinchweld.
5. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
6. Clean the inside of the roof glass panel surface with glass cleaner.
7. Cut the urethane adhesive applicator tip to specification.
8. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and continuous bead.
Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the rear of the roof opening 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 roof glass panel, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.
Install the roof glass panel on the vehicle aligning it with the markings made previously.
- Work the roof glass panel down using only vertical pressure.
- Carefully cut the excess side weatherstrip for best appearance to the existing weatherstrip.
- For front glass panel, tuck the front weatherstrip under the windshield lip.
- For rear glass panel, tuck the rear weatherstrip under the rear trim panel.
10. After the urethane adhesive has cured, clean the interior and exterior roof glass panel with glass cleaner.
Front glass panel
11. Install the LH and RH front sunshade tracks. For additional information, refer to Interior Trim and Ornamentation Sunshade Track.
Rear glass panel
12. Install the sunshade motor and both LH and RH rear sunshade tracks. For additional information, refer to Interior Trim and Ornamentation Sunshade Motor and Sunshade Track.
Front or rear glass panel
13. Install the headliner. For additional information, refer to Interior Trim and Ornamentation Service and Repair.