Body Side Window Replacement Extended Cab

Tools Required

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.

1. Apply masking tape to the painted surfaces around the stationary window in order to prevent paint damage.
2. Remove the rear quarter trim panel. Refer to Rear Quarter Trim Panel Replacement in Interior Trim.



3. Use J 39032 in order to cut the window from the pinchweld flange. Do this from inside the vehicle.



4. Remove the stationary window from the pinchweld flange with the aid of an assistant:



5. Keep the blade of the knife as close to the pinchweld flange as possible in order to leave a base of urethane on the window.
6. The stationary window reveal molding retains the urethane adhesive in the cavity between the body and the opening. If the stationary window revealmolding is damaged by cutting it too close to the window surface, replace the window.
7. Inspect the condition of the stationary 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.

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 present a clean primer only surface. 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 ® and PPG DP40 ®, or equivalent products are approved for this application.

8. After repairing the opening as indicated, perform the following steps:
9. Shake the pinchweld primer (#3 black) well.



10. Use a new dauber to apply the primer to any exposed painted surfaces ( or any scratches in the metal) of the flange in the bonding area.
11. Allow the primer to dry for approximately 10 minutes.

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



2. Use masking tape in order to mark the location of the stationary window in the opening.
3. Slit the masking tape at the top edge of the stationary window.
4. Remove the stationary window from the opening.
5. Place the stationary window inside up on a clean, protected surface.
6. If the original window is being reused, remove all but a thin film of the existing urethane adhesive from the window surface using a utility knife or equivalent.
7. Clean the inside surface of the stationary window with GM Glass Cleaner P/N 1050427 or equivalent.
8. If an extended method installation is being performed:

8.1.	Remove all but a thin film of the existing bead of adhesive from the pinchweld flange.

8.2.	It is not necessary to remove all traces of adhesive, but there should not be any mounds or loose pieces left.

8.3.	Shake the pinchweld primer (#3 black) well.

8.4.	Use a new dauber to apply the primer to the primed surface of the flange in the bonding area.

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

Important: Use the following procedure:

8.6.	Use care when applying the stationary window prep (#1 clear) in order to prevent the stationary window prep from running into the vision area of the stationary window. This primer dries almost instantly and may stain the viewing area of the stationary window.




9. If installing a new window:

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

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

9.3.	Wipe the primed area immediately with a lint free cloth.




10. Shake the stationary window primer (#2 black) well.

10.1.

Use a new dauber, to apply the stationary window primer (#2 black) to the areas of the stationary window (1) which prep (#1 clear) was applied.

10.2.

Allow the primer to dry for approximately 6 minutes.




11. Cut the tip of the applicator nozzle as follows:

11.1.

If short method installation is being used, cut the tip to provide an urethane adhesive bead of approximately 6.0 mm 1/4 in.).

11.2.

If extended installation method is being used, cut the tip to provide an adhesive bead of approximately 10.5 mm (0.14 in.) wide and 10.5 mm  (0.14 in) high.




12. Use a cartridge type caulking gun, to apply a smooth continuous bead of urethane adhesive as follows:
13. When using the short installation method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.



14. When using the extended installation method, use the edge of the stationary window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the (2) urethane adhesive to the inner surface of the (3) stationary window.
15. Use rubber suction cups, and with the aid of a assistant, install the stationary window into the opening.
16. Align the tape on the stationary window and the body.
17. Press the stationary window firmly into place.
18. Tape the stationary window to body in order to minimize movement.

18.1.

Remove any excess urethane adhesive that may have squeezed out from the body.

18.2.

Use a soft spray of water in order to watertest the stationary window immediately.

18.3.

Warm or hot water is preferred in order to accelerate the cure of adhesive.

18.4.

Do not direct a hard stream of high pressure water at fresh urethane adhesive.

Important: Inspect the stationary window for leaks.

19. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
20. Retest stationary window for leaks.
21. In order to properly cure the urethane adhesive, do the following:

•	Allow the vehicle to remain at room temperature of 22°C ( 72°F) at 30 percent or less relative humidity.

•	Allow a minimum of (6 hours) for the moisture curing urethane adhesive.

•	Allow a minimum of (1 to 1½ hours) for the chemical curing urethane adhesive.

•	Partially lower a door window to prevent pressure build ups when closing doors prior to urethane adhesive cure.

•	Do not drive the vehicle until the urethane adhesive is cured.

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

22. Remove the tape from the painted surfaces.
23. Install the rear quarter trim panel. Refer to Rear Quarter Trim Panel Replacement in Interior Trim.