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 windshield wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers/Washer Systems.

Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.

2. Cover the defroster grille outlets and protect the headliner as needed.

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.




3. Use safety glasses and gloves.
4. If both windshield and weatherstrip retainer is to be replaced do the following:




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

5. Use a utility knife to cut around the top part of the windshield retaining weatherstrip (1), this will release the urethane adhesive from the body.

Use the J 24402-A or J 39032 in order to remove the windshield.




6. Remove the windshield from the vehicle with the aid of an assistant.

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 windshield:

•	The flange of the windshield opening

•	The windshield reveal molding

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

•

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 the 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 1 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 (1) of the bonding area.
7. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.

1. Install the windshield weatherstrip retainer to the windshield, If the original weatherstrip retainer is damaged it must be replaced.
2. When the weatherstrip and the windshield are assembled together, keep the weatherstrip parallel with the windshield.



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



4. Use masking tape (1) in order to mark the location of the windshield in the opening.
5. Slit the masking tape at the top edge of the windshield.
6. With the aid of assistant and using suction cups remove the windshield from the opening.
7. Place the windshield inside up on a clean, protected surface.
8. If the original windshield is being reused remove all but a thin film of the existing urethane adhesive from the windshield surface by using a clean utility knife or razor blade scraper.
9. 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 remove all traces of the adhesive. Remove all mounds or loose pieces of urethane adhesive.

10. Use the extended method remove all but approximately 2 mm (3/64 in) of the existing bead of adhesive from the pinchweld flange.
11. Shake the pinchweld primer (black #3) for at least one minute.

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.

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) in the windshield. This primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly.

14. Use a new dauber in order to apply glass prep (clear #1) to the area approximately 10 mm to l6 mm (3/8 in to 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 one minute.



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.

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.

19. Allow the glass primer to dry for approximately 10 minutes.



20. Use 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.



21. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.



22. Apply a consistent bead of urethane adhesive completely around the windshield in between the lips of the weatherstrip.
23. Apply a consistent bead of urethane adhesive (1) across the top of the weatherstrip where it contacts the sheet metal.



24. Insert a string (approximately 5 mm to 6 mm in diameter) in between the lips of the weatherstrip.
25. After installing the string around one full turn, leave the string crossed at the bottom center of the windshield approximately 400 mm (15.7 in).



26. With the aid of an assistant, use the suction cups in order to install the windshield window into the opening.



27. Align the center of the windshield with the body and hold the windshield from the outside.
28. Using a helper inside the cab, pull the string from the inside toward the center of the windshield.

•	Fit the lips gradually into the body flange.

•	In order to keep the windshield from shifting to one side, support the windshield securely.

29. If the weatherstrip swells in one area, tap lightly with a rubber mallet in order to distribute the weatherstrip evenly.



30. Align the tape (1) lines on the windshield and the body.
31. Press the windshield firmly into place.
32. Tape the windshield to the body in order to minimize movement until the urethane adhesive cures.



33. 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.

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

38.1.

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

38.2.

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

38.3.

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

39. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in Wiper/Washer System.
40. Remove the protective coverings and tape from the vehicle and the headline.