Body - Convertible Top Back Glass Service Procedure
NUMBER: 23-022-07GROUP: Body
DATE: June 12, 2007
SUBJECT:
Convertible Backlite Removal and Installation Procedure
OVERVIEW:
This bulletin provides procedures for removing and installing the backlite on the convertible (soft) top.
MODELS:
2008 J527 Sebring Convertible, (Soft Top).
DISCUSSION:
The backlite on the convertible (soft) top is serviceable and can be removed and replaced using the appropriate procedures. This Service Bulletin should be shared with your sublet Glass Repair Companies and Body Shops.
PARTS REQUIRED:
REPAIR PROCEDURE:
HEADLINER REMOVAL:
1. Activate the convertible top and raise so backlite is vertical. While top is opening, touch close button to stop.
2. Remove pushpins, 12 across top of backlite, above headliner, see (Fig 2) and elastic straps, 1 per side, (attached to end pushpins).
3. Remove elastic straps, 1 per side, (attached to metal arm with pushpin).
4. Release plastic retainer inside vehicle at top and both sides of glass.
5. Remove rubber extrusion from flange at bottom of glass, inside vehicle.
6. Remove the headliner retainer from the rear bow to allow it to fold toward the front of the vehicle.
7. Pull headliner toward front of vehicle and clip to front edge of top.
REMOVE BACKLITE:
1. Remove heated rear glass electrical connectors from glass.
2. Remove retaining bolts inside vehicle for backlite, (18).
3. Protect top of windshield header with fender cover or equivalent. Lower top to rest on windshield header.
4. Mask fabric around perimeter of window opening on the outside with masking tape and paper.
5. With the help of 2 assistants, remove glass.
6. With one person in vehicle pushing out working back and forth from top corner to top corner, and two people outside, (one on each side), pulling carefully out on window assembly releasing butyl sealer from top.
7. While the window frame is being removed, butyl sealer will stretch. Carefully cut butyl sealer as close to fabric top as possible, (to avoid excess from remaining with fabric top).
8. Place backlite face down on protected surface.
9. Remove plastic clip, (edge of fabric at backlite opening) and 2 pushpins from both sides of opening.
10. Remove 2 rearmost nuts retaining fabric on left and right of glass, lift fabric off studs. Fold this corner up and off of 2 studs.
11. Remove T-patch from the vehicle roof glass mount panel and butyl from the 2 rear studs.
12. Remove all remaining butyl from fabric and mounting panel. (Check back side of fabric at lower inside corner). A plastic putty knife or trim stick cut like a chisel can be used on metal surfaces. Hand peel and roll with thumb from fabric surfaces. Work any remaining butyl on fabric toward window opening, making it as thin as possible.
CAUTION:
EXCESSIVE AMOUNTS OF BUTYL LEFT ON SURFACES MAY SQUEEZE OUT OF PERIMETER OF GLASS DURING INSTALLATION AND STAIN THE FABRIC TOP.
PREPARE TOP FOR INSTALLATION OF GLASS
1. Install butyl to the 4 rearmost studs, (2 on each side), see (Fig. 11).
2. Install T-Patch, p/n 68028362AA, as shown in (Fig. 11) on each side of backlite frame. Add a 1 in x 1 in (25 mm) square piece of butyl to inside of I-patch at bottom, (Toward Center of Vehicle).
3. Fold side fabric back in place and install plastic clip and pushpins on both sides of the opening.
4. Install 4 nuts on studs, (2 per side), at base of side fabric panels. Torque nuts to 5 Nm, (44 In lbs).
PREPARE BACKLITE ASSEMBLY FOR INSTALLATION:
1. If reusing original backlite, remove all butyl and tape from perimeter and clean using 3M General Purpose Adhesive Cleaner, p/n 0897 or equivalent.
2. Starting the end of the butyl rope at a LOWER corner of the backlite, fit butyl rope, p/n 68028371AA, inside the channel all the way around glass so there are NO breaks or seams in the butyl anywhere else in the glass frame.
3. Install a second butyl rope inside the other along the bottom of the glass.
4. Add square patch, p/n 68028357AA to each of the upper corners.
INSTALL REPLACEMENT GLASS:
NOTE:
To ease installation, 2 guide pins can be fabricated using M5 x 2Omm bolt, (or longer). Cut the head of the bolt off, (do NOT damage threads). Thread these pins in the center top and bottom of the backlite frame to ensure proper alignment.
CAUTION:
Be sure hands are clean for reassembly.
1. Install glass into top. Guide locating pins through holes in panel, (2 long removable pins, (if used) and 3 short fixed pins in glass frame).
2. Start at least 2 bolts on top and 2 bolts in bottom of glass frame and draw frame in, (by hand), compressing butyl.
3. Raise top so glass opening is vertical.
4. Start remaining bolts around perimeter and hand tighten.
5. Remove the 2 fabricated guide pins, (if used).
6. Install remaining bolts hand tight around perimeter of backlite.
7. Tighten bolts in 2 more stages working from the center top and center bottom toward the outside. Alternate areas to ensure consistent pressure around glass. Torque to 6 Nm, (53 In lbs). Torque only 1 time, otherwise top, (where window mounts) may collapse.
REASSEMBLE HEADLINER:
1. Connect electrical connectors to backlite.
2. Release clips retaining headliner to front of top installed in ~ above.
3. Install the headliner rear bow.
4. Install plastic clip to flange on top and sides of opening.
5. Install rubber extrusion along inboard, bottom side of glass.
6. Install elastic straps onto push pin, press pins in headliner to panel.
7. Attach elastic straps, (from headliner) to metal arm with pushpins.
8. Remove masking installed on fabric top.
9. Clean glass inside and out.
POLICY:
Information Only
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.