Windshield: Service and Repair
WINDSHIELDDESCRIPTION
The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended.
POWER KNIFE
The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended.
RECOMMENDED TOOLS AND ADHESIVE
- Fein(R) Power Cutout Knife
- Equalizer(R) Magnum, Interior Auto Glass Cut Out Knife
ADHESIVE, PRIMER AND CLEANER
The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended.
RECOMMENDED TOOLS AND ADHESIVE
The following urethane adhesive systems are OEM certified and conform to the FMVSS 212 windshield retention standard and the FMVSS 216 roof crush standard.
REMOVAL
EXTERIOR METHOD
The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended.
1. Remove inside rear view mirror.
2. Remove windshield wiper arms.
3. Remove cowl cover.
4. Place protective covers over instrument panel and hood.
Fig. 2:
5. Remove windshield A-pillar moldings (Fig. 2) using a suitable hook tool and trim stick.
Fig. 3:
6. Using a sharp cold knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences (Fig. 3). A power cutting device can be used if available.
7. Separate windshield from vehicle.
INTERIOR METHOD
The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended.
1. Remove inside rear view mirror.
2. Remove instrument panel top cover.
3. Remove A-pillar trim covers.
4. Place protective covers over instrument panel and hood.
5. Using a reciprocating or oscillating power knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences. Refer to instructions provided with equipment being used.
6. Remove windshield from vehicle.
INSTALLATION
CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use.
To avoid stressing the replacement windshield, the urethane bonding material on the windshield fence should be smooth and consistent to the shape of the replacement windshield. The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening.
1. Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers.
2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass.
3. Remove replacement windshield from windshield opening.
Fig. 4:
4. 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).
WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT.
5. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
6. Apply molding to Top of windshield.
7. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible.
8. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time.
9. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence.
10. Apply pinch weld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time.
11. Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence.
12. 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.
Fig. 5:
13. Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward molding is flush to roof line and A-pillars (Fig. 5).
14. Clean access urethane from exterior with Mopar(R), Super Clean or equivalent.
15. 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.
16. Install A-pillar moldings.
17. Install cowl cover and wipers.
18. Install inside rear view mirror.
19. After urethane has cured, remove tape strips and water test windshield to verify repair.