Back Window Glass: Service and Repair

REMOVAL

HINT: For step 2 to 10, refer to Headliner.

1. Access cab:
REMOVE REAR SEAT

2. Standard cab:
REMOVE FRONT DOOR SCUFF PLATES

3. Access cab:
REMOVE ACCESS DOOR SCUFF PLATES

4. REMOVE ASSIST GRIPS
5. Standard cab:
REMOVE FRONT PILLAR GARNISHES

6. Access cab:
REMOVE ROOF SIDE RAIL GARNISHES

7. REMOVE ROOM LIGHT
8. Standard cab:
REMOVE COAT HOOK

9. Standard cab:
REMOVE BACK PANEL UPPER GARNISH

10. REMOVE QUARTER TRIMS
11. REMOVE REAR PART OF ROOF HEADLINING
a. Standard cab:
Remove the 2 clips and rear part of the roof headlining.

b. Access cab:
Remove the 3 clips and rear part of the roof headlining.

12. REMOVE BACK WINDOW GLASS

a. Remove the 4 nuts.
b. Using a screwdriver, loosen the weatherstrip from the body.

NOTE: Be careful not to damage the body paint.

HINT: Tape the screwdriver tip before use.

c. Push piano wire through from the interior.
d. Tie both wire ends to wooden blocks or similar objects.

HINT: Apply protective tape to the outer surface to keep the surface from being scratched.

NOTE: When separating the glass, take care not to damage the paint and exterior.

e. Cut the adhesive by pulling the piano wire around it.

HINT: Cut the adhesive areas as shown in the illustration, leaving the adhesive where the stud bolts are.

f. Let the piano wire pass as shown in the illustration, cut off the adhered part to the stud bolts.
g. Remove the glass.

NOTE: Leave as much of the adhesive on the body as possible when cutting off the glass.

INSTALLATION

HINT: For step 8 to 17, refer to Headliner.

1. CLEAN AND SHAPE CONTACT SURFACE OF BODY

a. Using a knife, cut away any rough areas on the body.

HINT: Leave as much of the adhesive on the body as possible.

b. Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner.

2. POSITION GLASS

a. Place the glass in the correct position.
b. Check that all contacting parts of the glass rim are perfectly even.
c. Place reference marks between the glass and body.
d. Remove the glass.

3. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat Primer M to the exposed part of body on the vehicle side.

NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not coat Primer M to the adhesive.
- Do not keep any of the opened Primer M for later use.

4. Fixed type:
COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"

a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration.
b. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries.

NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.

5. Slide type:
COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"

a. Cut off the tip of the cartridge nozzle.

Part No. 08850-00801 or equivalent

HINT: After cutting off the tip, use all adhesive within the time described in the table.

b. Load the cartridge into the sealer gun.
c. Coat the glass with adhesive as shown in the illustration.

A: 8.0 mm (0.314 in.)
B: 12.0 mm (0.472 in.)

7. Slide type:
APPLY ADHESIVE

a. Cut off the tip of the cartridge nozzle.

Part No. 08850-00801 or equivalent

HINT: After cutting off the tip, use all adhesive within the time described in the table.

b. Load the cartridge into the sealer gun.
c. Coat the glass with adhesive as shown in the illustration.

A: 8.0 mm (0.314 in.)
B: 12.0 mm (0.472 in.)

8. INSTALL BACK WINDOW GLASS

a. Position the glass so that the reference marks are lined up, and press in gently along the rim.
b. Using a spatula, apply adhesive on the glass rim.
c. Use a scraper to remove any excess or protruding adhesive.

HINT: Confirm that the moulding is attached to the body panel as shown in the illustration.

d. Hold the back window glass in place securely with a protective tape or equivalent until the adhesive hardens.

NOTE: Take care not to drive the vehicle during the time described in the table.

9. INSPECT FOR LEAK AND REPAIR

NOTE: Conduct a leak test after the hardening time has elapsed.

Part No. 08833-00030 or equivalent

10. INSTALL REAR PART OF ROOF HEADLINING
a. Standard cab:
Install the rear part of roof headlining with the 2 clips.

b. Access cab:
Install the rear part of roof headlining with the 3 clips.

11. INSTALL QUARTER TRIMS
12. Standard cab:
INSTALL BACK PANEL UPPER GARNISH

13. Standard cab:
INSTALL COAT HOOK

14. INSTALL ROOM LIGHT
15. Access cab:
INSTALL ROOF SIDE RAIL GARNISHES

16. Standard cab:
INSTALL FRONT PILLAR GARNISHES

17. INSTALL ASSIST GRIPS
18. Access cab:
INSTALL ACCESS DOOR SCUFF PLATES

19. Standard cab:
INSTALL FRONT DOOR SCUFF PLATES

20. Access cab:
INSTALL REAR SEAT