Tools Required

J 42058 Frame Adapter Clamp

Notice: When replacing panels that involve servicing stationary glass, refer to GM Service Bulletin no. 43-9-48 before performing any priming or refinishing.

1. Remove the following panels and components to gain access to the windshield assembly:

•	Front fenders

•	Front wheelhouses

•	Windshield

•	Instrument panel assembly

2. Visually inspect for damage to the frame rails or wheelhouse mounting areas.
3. Restore as much of the damage as possible to specifications using three-dimensional measuring procedures. Use J 42058 if pulling and straightening of the vehicle are required.
4. Remove and relocate wiring as necessary to avoid damage.

Important: Use care not to damage the plenums. If they are damaged during the removal process, they should be replaced.




5. Drill out the close-end rivets securing the upper plenum to the windshield frame.
6. Apply heat to the upper plenum side of the bond area.
7. Pry up on the panel to remove it.
8. Apply heat and pry as necessary to break the windshield frame loose from the lower plenum.
9. From inside the vehicle, remove all hardware attaching the instrument panel supports to the windshield frame assembly.
10. Remove bolts attaching cross-car brace.
11. Heat and break loose adhesive bonds.
12. Remove brace from vehicle.



13. Remove bolts attaching windshield frame to the front hinge pillars.
14. Remove damaged windshield frame.

1. Remove all remaining adhesive.
2. Scuff all bonding surfaces to ensure proper adhesion.
3. Clean and prepare all bonding surfaces as necessary.
4. Prime all bare metal surfaces with PPGs DP90, or an equivalent epoxy anti-corrosion primer. Do not top-coat any bonding surface.



5. Apply adhesive to the bonding surfaces of the new windshield frame and install.

Important: Use US Chemical and Plastics 82007B System 2000 Structural Adhesive, a PLIOGRIP® Adhesive manufactured by Ashland Chemical Company, or equivalent. Note the 30 minute working time and 2½ to 3 hour cure time.

6. Save any and all brackets, mounting studs, and accessories for transfer to the new rear compartment panel.
7. Apply adhesive to attach lower plenum to windshield frame, drill holes and use close-end rivets (GM P/N 9418420, or equivalent) to hold plenum secure while adhesive cures.
8. Apply adhesive to the area that the cross-car brace bonds to the center tunnel assembly, and install brace and bolt into place.
9. Attach all instrument panel supports to the windshield frame assembly service part.



10. Apply adhesive to the upper plenum and install using close-end rivets in factory locations, to hold in place while adhesive cures.
11. Prime bare metal areas with an approved anti-corrosion primer per GM P/N 4901M-D refinish manual.

Important: Do not top coat any bonding surfaces.

12. Install all related panels and components.