Back Window Glass: Service and Repair

REAR WINDOW GLASS

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL

WARNING: To prevent glass splinters from entering eyes or cutting hands, wear safety glasses and heavy gloves when cutting glass from the vehicle.

1. Remove the parcel shelf.
2. Remove the high-mounted stoplamp.
3. Disconnect the rear window glass electrical connectors.







4. NOTE: Lubricate the existing urethane adhesive with water to aid the special tool when cutting the urethane adhesive.

Using the special tool, cut the urethane adhesive from the rear window glass starting at the top center and work toward the bottom corners.







5. Using the special tool, distance the rear window glass from the body.







6. Using the special tool, cut the remaining urethane adhesive and remove the rear window glass.
7. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld area.

INSTALLATION

CAUTION:
- After installing a new urethane-installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time for Essex 400-HV at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary.) Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond.
- Make sure urethanes and primers have not gone beyond the shelf life printed on the containers. Lids should be re-installed after use to maximize actual shelf life, which may be less than what is indicated once lids or seals are removed.

1. Dry fit the rear window glass. Make alignment marks with tape or non-staining grease pencil.







2. CAUTION: Avoid scratching the pinch weld area.

Trim the remaining urethane adhesive on the pinch weld to within specification.

3. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry.
4. If reinstalling the original rear window glass, remove the excess urethane adhesive from the rear window glass.
5. If a new rear window glass is to be installed, attach the new molding to the edge of the glass starting at the top center, then working out, then down the pillars and around the corners.
6. Clean the rear window glass with a non-alcohol based window cleaner.

7. NOTE: Wipe off the glass prep with a clean lint-free cloth immediately after each application because it flash dries.

If installing a new rear window glass, apply urethane glass prep twice around the surface to be urethaned.

8. If installing a new rear window glass, apply glass primer to the same area that was in the previous step. Allow five minutes to dry.







9. Cut the urethane adhesive applicator tip to specification.







10. Apply a bead of the urethane adhesive to the pinch weld.







11. Install the rear window glass aligning it to the marks made previously.
12. After the glass is set, check for water leaks and add urethane adhesive where needed.
13. Connect the rear window glass electrical connectors.
14. Install the package tray.