Grid Line and Terminal Repair

WARNING: MATERIALS CONTAINED IN THE REPAIR KIT (PART NUMBER 04549275) MAY CAUSE SKIN OR EYE IRRITATION. THE KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, WHICH ARE HARMFUL IF SWALLOWED. AVOID CONTACT WITH THE SKIN AND EYES. FOR SKIN CONTACT, WASH THE AFFECTED AREAS WITH SOAP AND WATER. FOR CONTACT WITH THE EYES, FLUSH WITH PLENTY OF WATER. DO NOT TAKE INTERNALLY. IF TAKEN INTERNALLY, INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY. USE WITH ADEQUATE VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE REACH OF CHILDREN. FAILURE TO FOLLOW THE WARNINGS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.

GRID LINE AND TERMINAL REPAIR

REAR WINDOW DEFOGGER GRID LINE REPAIR

Repair of the rear glass heating grid lines and bus bars can be accomplished using the Mopar(R) Rear Window Defogger Repair Kit (Part Number 04549275) or equivalent.

Grid Line Repair:

1. Mask the repair area with masking tape or use a template so that the conductive epoxy can be applied neatly. Extend the epoxy application onto the grid line or the bus bar on each side of the break.
2. Follow the instructions in the repair kit for preparing the damaged area.
3. Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the packaging. Fold the package in half and cut the center corner to dispense the epoxy
4. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19 millimeters (0.75 inch).
5. Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place it in the proper location on the bus bar. To prevent the terminal or pigtail wire from moving while the epoxy is curing, it must be wedged or clamped.
6. Carefully remove the masking tape or template.

CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a heat gun, or the glass may fracture.

7. Allow the epoxy to cure 24 hours at room temperature, or carefully use a heat gun for fifteen minutes. When using a heat gun, hold it approximately 25.4 centimeters (10 inches) from the repair and do not allow the glass surface to exceed 204° C (400° F).
8. After the conductive epoxy is properly cured, check the operation of the rear window defogger glass heating grid.

REAR WINDOW DEFOGGER TERMINAL REPAIR - HARD TOP MODELS

Repair of the rear glass heating grid terminal(s) on hard top models can be accomplished using the Mopar(R) Rear Window Defogger Repair Kit (Part
Number 04549275) or equivalent.
1. If the grid terminal(s) is broken and a portion of the terminal is still attached to the heating grid, remove the portion of the clip remaining in the wire harness connector(s).
2. Mask the areas so the conductive epoxy can be extended onto the adjacent grid line(s) as well as the bus bar.
3. Apply a thin layer of conductive epoxy to the area where the terminal(s) where fastened and to the adjacent grid line(s).

NOTE: To prevent the terminal(s) from moving while the epoxy is curing, a wedge or clamp must be used.

4. Apply a thin layer of conductive epoxy on the terminal(s) and properly orient the terminal(s) at the desired location(s).
5. Carefully remove the masking tape.

CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a heat gun, or the glass may fracture.

6. Allow the epoxy to cure 24 hours at room temperature, or carefully use a heat gun for fifteen minutes. When using a heat gun, hold it approximately 25.4 centimeters (10 inches) from the repair and do not allow the glass surface to exceed 204° C (400° F).

NOTE: To ensure proper installation, do not attach the wire harness connector(s) to the terminal(s) until the epoxy is completely cured.

7. After the conductive epoxy has properly cured, remove the wedge or clamp from the terminal(s), reconnect the wire harness connector(s) and verify operation of the rear window defogger.

REAR WINDOW DEFOGGER TERMINAL REPAIR - CONVERTIBLE MODELS

CAUTION: Do not use a flame type solder gun or an electric solder gun rated greater than 500 watts or damage to the glass may occur.

If the rear window defogger grid terminal (s) on convertible models is damaged or separated from the rear window, the new grid terminal (s) must be securely fastened to the rear window defogger bus bar by soldering.
1. If the grid terminal(s) is broken and a portion of the terminal is still attached to the heating grid, remove the portion of the clip remaining in the wire harness connector(s).

CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a solder gun, or the glass may fracture.

2. If the grid terminal(s) is broken and a portion of the terminal is still attached to the rear window defogger bus bar, apply heat with a solder gun to the portion of the terminal on the glass until the solder starts to flow. Remove the terminal and carefully smooth the solder on the bus bar.

NOTE:
- Wait five minutes for the glass to cool after applying heat with a solder gun before proceeding.
- Use care when cleaning the mating surfaces. Excessive abrasion may wear away the copper grid surface causing grid continuity to be lost.

3. Clean the mating surfaces on the grid bus bar and the new terminal(s) with "000" Extra Fine Steel Wool or an equivalent.

NOTE: The terminal attaching clip(s) must face outboard. Failure to reorient the terminal(s) may result in an additional failure.

4. Properly orient the new terminal(s) with the attaching clip facing outboard in the original locations) on the grid bus bar and hold the terminal(s) with a metal pick or other suitable pointed tool.

CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a solder gun, or the glass may fracture.

NOTE: New rear window defogger terminals are presoldered and fluxed. Do not reuse a terminal if it has been previously heated.

Place the solder gun onto the new terminal(s) and heat the terminal until the solder flows. Remove the solder gun and continue to hold the terminal in the correct position for an additional five seconds.

5. Allow the solder to cool for ten minutes.

NOTE: To ensure proper installation, do not attach the wire harness connector(s) to the terminal(s) until the solder is completely cooled.

6. After the solder has cooled, reconnect the wire harness connector(s) and verify operation of the rear window defogger.