Tools Required

Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and inner trim of the window.

1. Remove the rear door trim panels in order to gain access the rear window removal. Refer to Rear Door Trim Panel Replacement - Left Side , or to Rear Door Trim Panel Replacement - Right Side in Body Rear End.

Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

2. Use safety glasses and gloves.




Important: Keep the cutting edge of the tool against the rear window. This will allow the urethane adhesive to be separated from the rear window. Leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.

3. Use theJ 24402-A , or to J 39032 in order to cut the rear window from the pinchweld flange. Do this from inside the vehicle in order to protect the outer paint surface.



4. With the aid of an assistant, use the suction cups in order to lift the rear window from the opening.

1. Verify all primers and urethane adhesive are within expiration dates.

Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392 (Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

2. Inspect the following components for the causes of a broken rear window:

•	The flange of the rear window opening

•	The rear window reveal molding

3. Inspect for any of the following problems in order to help prevent future breakage of the rear window:

•

High weld

•	Solder spots

•	Hardened spot weld sealer

•	Any other obstruction or irregularity in the pinchweld flange

Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are required, the pinchweld flange must be refinished in order to restore the bonding area strength. If paint repairs are required, mask the flange bonding area prior to applying the color coat in order to provide a clean primer only surface. Materials such as BASF DE17®, DuPont  2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120 and 5130® products are approved for this application.

4. After repairing the opening as indicated, perform the following steps:

4.1.	Inspect the condition of the windshield opening and the adhesive bead to determine which installation method should be used. Refer to Short Method Description or Extended Method Description for guidelines.

4.2.	Remove no more of the urethane adhesive from the pinchweld than necessary in order to maintain the original shape. This will ensure the proper clearance between the windshield and the pinchweld flange.

4.3.	Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.

4.4.	Clean around the edge of the inside surface of the windshield with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

5. After repairing the opening as indicated, shake the pinchweld primer (black #3) for at least one minute.

Caution: Failure to prep the area prior to the application of primer may cause insufficient bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.




6. Use a new dauber to apply the pinchweld primer (black #3) to the surface of the bonding area.
7. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.



8. If the original reveal molding is damaged it must be replaced, if equipped.

Install the new rear window reveal molding (1).

9. Start from the center and hand press the rear window reveal molding (1) onto the rear window (2).



10. With the aid of an assistant, dry fit the rear window in the opening in order to determine the correct way to position the rear window in the opening.
11. Use masking tape in order to mark the location of the rear window in the opening.
12. Slit the masking tape at the top edge of the rear window.
13. With the aid of an assistant and the suction cups, remove the rear window.
14. Place the rear window inside up on a clean, protected surface.
15. If the original rear window is being reused, remove all but approximately 2 mm (3/64 in) of the existing urethane adhesive from the rear window surface, using a utility knife or razor blade scraper.

Important: Do not remove all traces of the adhesive. Remove all mounds or loose pieces of urethane adhesive .

16. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the existing bead of adhesive from the pinchweld flange.
17. Clean around the edge of the inside surface of the windshield with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

Important: Do not apply the (black #3) primer to the existing bead of the urethane adhesive. Apply the primer only to nicks, scratches or the primed surfaces.

18. Shake the pinchweld primer (black #3) for at least one minute.
19. Use a new dauber to apply the primer to the surface of the pinchweld flange.
20. Allow the pinchweld primer to dry for approximately 10  minutes.
21. If the extended method is being performed, do the following:




Important: Use care when applying the prep (clear #1) to the rear window. This primer dries almost instantly and may stain the viewing area of the rear window if not applied evenly.

22. If installing a new non encapsulated window:

22.1.

Use a new dauber, to apply the rear window prep (clear #1) to an area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the rear glass inner surface (reference the illustration of the primer/bonding areas).

22.2.

Apply the rear window prep (clear #1) to any exposed edges of the window.

22.3.

Wipe the primed window area immediately with a lint-free cloth.

22.4.

Shake the glass primer (black #2) for at least one minute.

23. If installing a new encapsulated window:

23.1.

Use a new dauber, to apply the rear window prep (clear #1) to an area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the rear glass inner surface (reference the illustration of the primer/bonding areas). The glass must be installed within 8 hours after applying the primer to the glass.

23.2.

The primed surface of the glass must be kept clean.

23.3.

Allow the glass primer to dry for approximately 10 minutes.

24. Shake the rear window primer (black #2) for at least 1 minute.



25. Use a new dauber, in order to apply the rear window primer (black #2) to the areas of the rear window (1) to which prep (clear #1) was applied.
26. Allow the primer to dry for approximately 10 minutes.



27. If using the short method, cut the tip of the applicator nozzle in order to provide a bead of 6.0 mm (1/4 in).
28. If using the extended method, cut the applicator nozzle in order to provide a bead 10.5 mm (0.14 in) wide and 10.5 mm (0.14 in) high.



29. Use a cartridge-type caulking gun, apply a smooth continuous bead of new urethane adhesive around the edge of the rear window where the primer was applied.
30. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.



31. When using the extended method, use the edge of the rear window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive to the inner surface of the rear window.



32. With the aid of an assistant, use the suction cups in order to install the rear window into the opening.
33. Align the tape on the rear window and on the body.
34. Press the rear window firmly into place in order to wet-out and seat the urethane adhesive.
35. Tape the rear window in two places to the body in order to minimize movement until the urethane adhesive cures.



36. Clean any excess urethane adhesive from the body.




Important: Use a soft spray of warm water in order to immediately water test the rear window.

37. Do not direct a hard stream of high pressure water at the fresh urethane adhesive.
38. Inspect the rear window for leaks.
39. If you have found any leaks, use a plastic paddle in order to apply extra urethane at the leak point.
40. Retest the rear window for leaks.

Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

•	For the moisture-curing type of urethane adhesive, allow a minimum of 6 hours at 21°C (70°F) or greater and with at least 30 percent relative humidity. Allow at least 24 hours for the complete curing of the urethane adhesive.

•	For the chemical-curing type of urethane adhesive, allow a minimum of 1 hour .

Do NOT physically disturb the repair area until after these minimum times have elapsed.
41. The following conditions must be maintained to properly cure the urethane.

41.1.

Partially lower a door rear window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.

41.2.

Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.

41.3.

Do not use compressed air in order to dry the urethane adhesive.

42. Install the rear door trim panels which were removed in order to gain access to the rear window removal. Refer to Rear Door Trim Panel Replacement - Left Side , or to Rear Door Trim Panel Replacement - Right Side in Body Rear End.
43. Remove the protective coverings and tape from the vehicle and the headliner.