Rear Window Replacement Utilityw/ Cargo Door

Tools Required

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

1. Remove the window garnish molding from the door frame. Refer to Rear Door Trim Panel Replacement 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.



3. Disconnect the electrical connector from the window defogger on the window, if equipped.




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

4. Using the J 24402-A or J 39032 in order to remove the window. Do this from inside the vehicle to protect the outer surface of the paint.



5. With the aid of an assistant, remove the window from the opening.

1. With the aid of an assistant, dry fit the window in the opening in order to determine the correct way to position the window in the opening.
2. Use masking tape in order to mark the location of the window in the opening.
3. Slit the masking tape at the top edge of the window.
4. With the aid of assistant and using suction cups remove the window from the opening.
5. Place the window inside up on a clean, protected surface.
6. Inspect for any of the following problems in order to help prevent future breakage of the window:
7. Inspect the following components for the causes of a broken window:

•	The flange of the window opening

•	The window reveal molding

8. Inspect for any of the following problems in order to help prevent future breakage of the 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.

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

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

9.2.	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 window and the pinchweld flange.

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

9.3.	If the original window is being reused remove all but a thin film of the existing urethane adhesive from the window surface by using a clean utility knife or razor blade scraper.

9.4.	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.

9.5.	After repairing the opening, remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.

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

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.

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

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.





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

11. Shake the pinchweld primer (black #3) for at least 1 minute.
12. Use a new dauber to apply the primer to the surface of the pinchweld flange.
13. Allow the pinchweld primer to dry for approximately 10 minutes.




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

14. Use a new dauber in order to apply glass prep (clear #1) to the area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the window inner surface.



15. Apply a second coat of the glass prep number (clear #1) to the same area of the glass.
16. Wipe the glass primed area immediately with a clean lint free cloth.



17. Shake the glass primer (black #2) for at least 1 minute.

The glass primer (black #2) is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.

18. Use a new dauber in order to apply the glass primer (black #2) to the same areas (2) that glass prep (clear #1) was applied.
19. Allow the glass primer to dry for approximately 10 minutes.



20. 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).
21. If using the extended method, cut the applicator nozzle in order to provide a bead of 12.7 mm (1/2 in) wide and 12.7 mm (1/2 in ) high.



22. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.
23. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.



24. When using the extended method, use the edge of the window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (1) to the inner surface of the window (3).

If applying urethane adhesive to the inside edge of the window reveal molding (1) use the window reveal molding as a guide for the nozzle.

25. With the aid of an assistant, use the suction cups in order to install the window into the opening.
26. Align the tape lines on the window and the body.
27. Press the window firmly into place.
28. Tape the window to the body in order to minimize movement until the urethane adhesive cures.



29. Clean any excess urethane adhesive from the body.




Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.

30. Use a soft spray of warm water in order to immediately water test the window.
31. Inspect the window for leaks.
32. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
33. Retest the 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.
34. The following conditions must be maintained to properly cure the urethane:

34.1.

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

34.2.

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

34.3.

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

1. Connect the electrical connector to the window defogger on the window, if equipped.
2. Install the window garnish molding to the door frame. Refer to Rear Door Trim Panel Replacement in Body Rear End.
3. Remove the protective coverings and tape from the vehicle and headliner.

Rear Window Replacement Pickup

Tools Required

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

1. Remove the window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement in Interior Trim.
2. Remove both rear seat headrests (extended cab). Refer to Head Restraint Replacement in Seats.
3. Lower rear seat back.

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.

4. Use safety glasses and gloves.



5. Using a sharp utility knife, make a preliminary cut around the perimeter of the window. Cut as close to edge of the window as possible.

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

6. Use the J 24402-A or the J 39040 in order to cut the window from the pinchweld flange. Do this from inside the vehicle in order to protect the outer paint surface.
7. Open the window, if equipped.



8. With the aid of an assistant, remove the window from the opening.

1. With the aid of an assistant, dry fit the window in the opening in order to determine the correct way to position the window in the opening.



2. Use masking tape (1) in order to mark the location of the window in the opening.
3. Slit the masking tape at the top edge of the window.
4. With the aid of assistant and using suction cups remove the window from the opening.
5. Place the window inside up on a clean, protected surface.
6. Inspect for any of the following problems in order to help prevent future breakage of the window:
7. Inspect the following components for the causes of a broken window:

•	The flange of the window opening

•	The window reveal molding

8. Inspect for any of the following problems in order to help prevent future breakage of the 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.

9. After repairing the opening do the following.
10. Inspect the condition of the window opening and the urethane adhesive bead to determine which installation method should be used. Refer to Short Method Description or Extended Method Description for guidelines.
11. 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 window and the pinchweld flange.

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

12. If the original window is being reused remove all but a thin film of the existing urethane adhesive from the window surface by using a clean utility knife or razor blade scraper.
13. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the existing bead of urethane adhesive from the pinchweld flange.
14. Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.
15. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

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.

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

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.





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

17. Shake the pinchweld primer (black #3) for at least 1 minute.

Use a new dauber to apply the pinchweld primer (black #3) to the surface (1) of the bonding area on the body only.

18. Allow the primer to dry for approximately 10 minutes.




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

19. Use a new dauber in order to apply glass prep (clear #1) to the area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the window inner surface.



20. Apply a second coat of the glass prep number (clear #1) to the same area of the glass.
21. Wipe the glass primed area immediately with a clean lint free cloth.



22. Shake the glass primer (black #2) for at least 1 minute.
23. Use a new dauber in order to apply the glass primer (black #2) to the same areas (2) that glass prep (clear #1) was applied.
24. The glass primer (black #2) is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.
25. Allow the glass primer to dry for approximately 10 minutes.



26. 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).
27. If using the extended method, cut the applicator nozzle in order to provide a bead of 12.7 mm (1/2 in) wide and 12.7 mm (1/2 in ) high.



28. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.
29. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.



30. When using the extended method, use the edge of the window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (1) to the inner surface of the window (3).

If applying urethane adhesive to the inside edge of the window reveal molding (1) use the window reveal molding as a guide for the nozzle.




31. With the aid of an assistant, install the window to the opening.
32. Align the tape lines on the window and the body.
33. Press the window firmly into place.
34. Tape the window to the body in order to minimize movement until the urethane adhesive cures.



35. Clean any excess urethane adhesive from the body.




Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.

36. Use a soft spray of warm water in order to immediately water test the window.
37. Inspect the window for leaks.
38. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
39. Retest the 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.
40. The following conditions must be maintained to properly cure the urethane adhesive:

40.1.

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

40.2.

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

40.3.

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

41. Install the window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement in Interior Trim.
42. Install both rear seat headrests (extended cab). Refer to Head Restraint Replacement in Seats.
43. Raise the rear seat back.
44. Remove the masking tape from the area around the window in order to protect the painted surfaces from damage and to protect the headliner.