Description and operation. Removal and installation

Stationary glass

DESCRIPTION

Windshields are made of two pieces of glass with a plastic inner layer. Windshields and selected stationary glass are structural members of the vehicle. The windshield glass is bonded to the windshield frame with urethane adhesive.

OPERATION

Windshields and other stationary glass protect the occupants from the effects of the elements. Windshields are also used to retain some airbags in position during deployment. Urethane bonded glass is difficult to salvage during removal. The urethane bonding is difficult to cut or clean from any surface.

Before removing the glass, check the availability of replacement components.

Windshield safety precautions

WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.

ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS.

CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers.

Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield.

Windshield

REMOVAL

(1) Remove rear view mirror.

(2) Remove wipers and cowl grille.

(3) With doors open, remove the weatherstrip from the side windshield moldings.

(4) Remove the screws attaching the side windshield molding to the A-pillars.

(5) Cut urethane bonding from around windshield using a suitable sharp cold knife (Fig. 1).

(6) Using a long knife, cut urethane bonding from inside the cab at the base of the windshield.

Fig. 1 Cut Urethane Around Windshield

1 - WINDSHIELD

2 - COLD KNIFE

INSTALLATION

WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use.

CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result.

The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers located on the cowl at the bottom of the windshield opening (Fig. 2) should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the windshield opening.

(1) Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation. Remove replacement windshield from windshield opening (Fig. 3).

(2) Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 4).

(3) Clean inside of windshield with MOPAR Glass Cleaner and lint-free cloth.

(4) Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lint- free cloth.

(5) Apply the header molding to the windshield.

(6) Apply pinchweld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time.

(7) Apply a 13mm (1/2 in.) high and 10mm (3/8 in.) wide bead of urethane around the perimeter of windshield.

At the bottom, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the three sides where the molding is on the glass, follow the edge of molding. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator (Fig. 5).

(8) With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers.

(9) Slowly lower windshield glass to the fence opening guiding the lower corners into proper position.

Beginning at the bottom and continuing to the top, push glass onto fence along the A-Pillars. Push windshield inward to the fence at the bottom corners.

(10) Clean excess urethane from exterior with MOPAR Super Clean or equivalent.

(11) Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures.

(12) Install new screws attaching the side windshield moldings to the A-pillars.

(13) Install the weatherstrip onto side windshield moldings.

(14) Install cowl grille and wipers.

(15) Install rear view mirror.

(16) After urethane has cured, remove tape strips and water test windshield to verify repair.

Fig. 2 Support Spacers

1 - WINDSHIELD

2 - SPACERS

3 - SUPPORTS

Fig. 3 Center Windshield and Mark at Support Spacers

1 - WINDSHIELD

2 - INDEX MARKS

3 - SUPPORT SPACERS

Fig. 4 Work Surface Set up and Molding Installation

1 - WINDSHIELD AND MOULDINGS

2 - URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM EDGE

3 - BLOCKS

Rear door stationary glass

REMOVAL

(1) Remove trim panel.

(2) Remove waterdam.

(3) Remove inner beltline weatherstrip (4) Remove outer beltline weatherstrip.

(5) Remove door glass from door.

(6) Remove bolt attaching bottom of rearward run channel to door inner panel.

(7) Remove nuts attaching stationary glass to door (Fig. 6).

Fig. 5 Applicator Tip

1 - APPLICATOR TIP

(8) Separate rearward run channel/stationary glass from door.

(9) Pull to separate stationary glass from run channel.

Fig. 6 Rear Door Stationary Glass

1 - RUN CHANNEL WITH STATIONARY GLASS

2 - REAR DOOR

3 - REGULATOR

4 - RUN CHANNEL

5 - DOOR GLASS

INSTALLATION

(1) Ensure glass and run channel are clean.

(2) Apply butyl adhesive to glass and insert in glass run channel.

(3) Install nuts attaching stationary glass to door.

Tighten nuts to 3 N*m (30 in. lbs.) torque (Fig. 6).

(4) Install bolt attaching bottom of rearward run channel to door inner panel.

(5) Position door glass in door.

(6) Install door glass to regulator.

(7) Install outer beltline weatherstrip.

(8) Install inner beltline weatherstrip (9) Install waterdam.

(10) Install trim panel.

Quarter window glass

REMOVAL

(1) Remove quarter panel trim.

(2) Carefully pull down headliner to access upper nuts attaching quarter window glass to pinchweld and remove nuts.

(3) Remove nuts attaching quarter window glass to pinchweld (Fig. 7).

(4) Using razor knife, cut butyl sealer between the mounting studs attaching glass to pinchweld.

(5) Push glass from opening.

Fig. 7 Quarter Window Glass

1 - QUARTER GLASS

2 - STUD

3 - NUT

INSTALLATION

The pinchweld should be cleaned of all old butyl sealer.

(1) Apply 6 mm (0.25 in.) of butyl tape around perimeter of glass assembly encapsulation track.

Ensure the butyl tape is wrapped around the mounting studs.

(2) Place glass into opening and insert mounting studs through holes in pinchweld.

(3) Install nuts attaching quarter window glass to pinchweld. Tighten nuts to 4.5 N*m (40 in. lbs.) torque.

(4) Install interior trim.

Liftgate backlite

REMOVAL

Refer to the Windshield paragraph of this section for all warnings and cautions.

(1) Remove liftgate upper trim panel.

(2) Remove CHMSL.

(3) Remove rear window wiper arm, if equipped.

(4) Remove side moldings.

(5) Cut urethane bonding from around liftgate backlite using a suitable sharp cold knife. A pneumatic cutting device can be used if available.

(6) Separate backlite from vehicle.

INSTALLATION

CAUTION: Open a window before installing backlite.

If a door is slammed before urethane is cured, water leaks can result.

The window opening fence should be cleaned of old urethane bonding material.

(1) Clean inside of backlite with Mopar Glass Cleaner or equivalent and lint-free cloth.

(2) Apply PVC (vinyl) primer 25 mm (1 in.) wide around edge of backlite. Wipe with clean/dry lint-free cloth.

(3) Apply fence primer around edge of fence. Allow at least eighteen minutes drying time.

(4) Install new upper and lower seals on liftgate backlite (Fig. 8).

(5) Apply a 12 mm (0.4 in.) bead of urethane around window opening fence.

Position backlite into window opening (Fig. 9).

Fig. 8 Liftgate Backlite Seals

1 - UPPER SEAL

2 - LIFTGATE BACKLITE

3 - LOWER SEAL

Fig. 9 Liftgate Backlite

1 - BACKLITE

2 - LIFTGATE