with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.

It is difficult to salvage a windshield during the

removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.

WARNING

WINDSHIELD SAFETY PRECAUTIONS

WARNING:

NOT

OPERATE

THE

VEHICLE

WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER

DOES

NOT

RECOMMEND

GLASS

ADHESIVE

BRAND.

TECHNICIANS

SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES

THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER’S

DIRECTIONS

FOR

CURING

TIME

SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN

CONTACT

WITH

URETHANE

ADHESIVE

SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
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.

REMOVAL

WINDSHIELD 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 wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.

(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.

STATIONARY GLASS

23 - 105

(4) Remove A-pillar trim panels.
(5) Place protective covers over instrument panel

and hood.

(6) Remove windshield molding. Using pliers, pull

outward on molding at the bottom of A-pillars.

(7) Using a sharp cold knife, cut urethane adhe-

sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 1). A power
cutting device can be used if available.

(8) Remove windshield from vehicle.

WINDSHIELD REMOVAL – INTERIOR METHOD

(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to

Group 8E, Instrument Panel and Systems.

(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 the equip-
ment being used.

(6) Remove windshield from vehicle.

INSTALLATION

The urethane adhesive holding the windshield to

CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger 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 open-
ing against the compression 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 wind-

shield opening.

(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 par-
allel 75 cm (2.5 ft.) apart (Fig. 2).

WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER

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) Install molding to perimeter 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 vis-
ible.

(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 wind-
shield fence.

(10) Apply pinch weld primer 19 mm (0.75 in.)

wide around the windshield fence. Allow at least
three minutes drying time.

(11) If a low viscosity urethane adhesive is used,

install compression spacers on the fence around the
windshield opening (Fig. 3).

(12) Apply a 10 mm (0.4 in.) bead of urethane on

center line of windshield fence.

(13) With the aid of a helper, position the wind-

shield over the windshield opening.

(14) Slowly lower windshield glass to windshield

opening fence. Guide the molding into proper position
as necessary. Push windshield inward until molding
is flush to roof line and A-pillars (Fig. 3).

(15) Clean access urethane from exterior with

Mopar

t Super Kleen or equivalent.

Fig. 1 CUT URETHANE AROUND WINDSHIELD

1 - COLD KNIFE
2 - WINDSHIELD

23 - 106

STATIONARY GLASS

WINDSHIELD (Continued)

(16) 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.

(17) Install A-pillar trim panels.
(18) Install cowl cover and wipers.
(19) Install inside rear view mirror.
(20) After urethane has cured, remove tape strips

and water test windshield to verify repair.

SLIDING DOOR GLASS

REMOVAL

The temperature of the vehicle should be at least

21° C (70° F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.

(1) Remove interior trim as necessary to gain

access attaching locations on back of glass.

(2) Remove nuts holding stationary glass to fence.
(3) Using razor knife, cut butyl sealer holding

glass to fence from between the mounting studs (Fig.
4).

(4) Push glass from opening.

INSTALLATION

The temperature of the vehicle should be at least

21° C (70° F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.

The stationary glass fence should be cleaned of all

old butyl sealer.

(1) Apply a 6 mm (0.25 in.) butyl tape around

perimeter of glass assembly encapsulation track.
Ensure that the butyl tape is wrapped around the
mounting studs.

(2) Place the glass into the opening and insert

mounting studs through holes in fence.

(3) Install nuts to hold stationary glass to fence.

CAUTION: Tighten nuts to 3.4 N·m (30 in. lbs.)
torque in the sequence indicated. Do not over
torque, or glass breakage may result (Fig. 4).

(4) Install interior trim. (Refer to 23 - BODY/

DOORS - SLIDING/TRIM PANEL - INSTALLATION)

(5) Verify alignment and flushness.

Fig. 2 WORK SURFACE SET UP AND MOLDING

INSTALLATION

1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS

Fig. 3 LOWER WINDSHIELD INTO POSITION

1 - WINDSHIELD
2 - COMPRESSION SPACERS

Fig. 4 SLIDING DOOR STATIONARY GLASS

1 - NUMBERS INDICATE THE TIGHTENING SEQUENCE
2 - 6 mm BEAD OF BUTYL TAPE
3 - BODY SIDE/SLIDING DOOR GLASS

STATIONARY GLASS

23 - 107

WINDSHIELD (Continued)

Content .. 458 459 460 461 ..