Fixed Glass

BACKLITE

REMOVAL






CAUTION: It is difficult to salvage the backlite during the removal operation. The backlite is part of the structural support for the roof. The urethane bonding used to secure the glass to the fence is difficult to cut or clean from any surface. Since the molding is set in urethane, it is unlikely it would be salvaged. Before removing the backlite, check the availability from the parts supplier.

NOTE: The backlite is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the backlite.

1. Roll down door glass.
2. Remove headliner (9).






3. On extended cab models remove the upper c-pillar trim (2).






4. On double cab models remove the upper c-pillar trim (2).






5. Disconnect the rear window defogger electrical connector (1), if equipped.






6. Bend backlite retaining tabs (2) inward against glass.
7. Using a suitable pneumatic knife from inside the vehicle, cut urethane holding backlite frame to opening fence.
8. Separate glass (1) from vehicle.

INSTALLATION

Preparation Before Backlite Installation






1. Manually remove as much urethane adhesive as possible from around the fence opening. For any remaining urethane that exhibits a cohesive failure at the fence, trim the remaining urethane bead (1) to a 1 to 2 mm thick layer. Bonding of the new urethane will be directly onto this 1 to 2 mm thick layer on the fence.
2. The fence must be cleaned with a new 100% alcohol wipe.






3. Apply a solid or even black layer of primer (1) to the fence (2) and allow to dry for 5 minutes.






4. Apply black-out primer to backlite opening fence.
5. Apply a 13 mm (0.5 in.) (2) X 9.5 mm (0.375 in) (1) bead of urethane around the perimeter of the window frame bonding surface.

CAUTION: Bead location, close to the metal edge, is critical to avoid urethane "squeeze out".






6. Set glass (1) on lower fence and move glass forward into opening using the alignment pins to guide the backlite into position.
7. Firmly push glass (1) against rear window glass opening fence.
8. Bend tabs (2) around edges of backlite opening fence to retain glass.
9. Clean excess urethane from exterior with a cleaning solvent.
10. Allow urethane to cure at least 24 hours (full cure is 72 hours).
11. Water test to verify repair before returning vehicle to service.

NOTE: The backlight must be installed within 5 minutes of applying the urethane bead.

1. Clean urethane adhesive from around backlite opening fence.
2. If necessary, apply black-out primer to outer edge of replacement backlite frame (1).
3. If black-out primer was pre-applied on backlite, clean bonding surface with Isopropyl alcohol and clean lint free cloth. Allow 5 minutes for drying time.






12. Connect the rear window defogger electrical connector, if equipped.






13. On extended cab models, install the upper c-pillar trim (2).






14. On double cab models, install the upper c-pillar trim (2).






15. Install the headliner (6).