Back Window Glass: Service and Repair

Rear Window Replacement

NOTE:

- Put on gloves to protect your hands.
- Wear eye protection while cutting the glass adhesive with piano wire.
- Use seat covers to avoid damaging any surfaces.
- Do not damage the rear window defogger grid lines or the terminals.

1. Remove these items:

- Hatch trim panel Interior Trim Removal/Installation - Hatch Area
- Rear window wiper motor Rear Window Wiper Motor Replacement
- High mount brake light Service and Repair

2. Disconnect the rear window defogger terminals (A), and remove the rear window trim (B).





3. If the original window will be reinstalled, make alignment marks across the window and the body with a grease pencil.

4. Apply protective tape along the inside and outside edges of the tailgate. Make a hole with an awl through the adhesive from inside the vehicle at a corner of the rear window. Push the piano wire through the hole, and wrap each end around a piece of wood.

5. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window (B) as possible to prevent damage to the tailgate, and carefully cut through the adhesive (C) around the entire rear window.






Cutting positions





6. Carefully remove the rear window.

7. Scrape smooth the original adhesive with a knife until there is a thickness of about 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange:

- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove the fasteners from the tailgate.

8. Clean the tailgate bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the surface.

9. If you are reinstalling the original rear window, scrape off all of the original adhesive and the rubber dams from the rear window with a putty knife. Clean the bonding surfaces on the inside face and the edge of the rear window with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.

10. Attach the upper corner fasteners (A) and the lower corner fasteners (B) with adhesive tape. Attach the upper rubber dam (C) and the lower rubber dam (D) with adhesive tape to the inside surface of the rear window (E) as shown:

- Make sure the fasteners and the rubber dams line up with alignment marks (F).
- Be careful not to touch the rear window where adhesive will be applied.





11. Attach the corner fasteners (A, B) with adhesive tape to the tailgate as shown.






12. Set the rear window in the opening, and center it. Make alignment marks (A) across the rear window, tailgate, and body with a grease pencil at the four points shown. Be careful not to touch the rear window where adhesive is applied.





13. Remove the rear window.

14. Apply a light coat of glass primer to the edge of the rear window (A) along the upper rubber dam (B) and the lower rubber dam (C) as shown, then lightly wipe it off with gauze or cheesecloth:

- Apply the glass primer to both side areas of the rear window using the printed dots (D) on the rear window as a guide.
- Do not apply body primer to the rear window, and do not mix up the body and glass primer applicators.
- Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed.
- Keep water, dust, and abrasive materials away from the primed surface.





15. Carefully apply a light coat of body primer to any exposed paint around the flange where new adhesive is applied. Let the primer dry for at least 10 minutes:

- Do not apply body primer to any remaining original adhesive on the flange.
- Be careful not to mix up the body and glass primer applicators.
- Never touch the primed surfaces with your hands.





16. Cut a "V" in the end of nozzle (A) on the adhesive cartridge as shown.






17. Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) on the glass primer trace (B) you applied on step 14, and around the edge of the rear window (C) as shown:

- Apply the adhesive within 30 minutes after applying the glass primer.
- Make a slightly thicker bead at each corner.





18. Hold the rear window over the opening with suction cups, align it with the alignment marks you made in step 12, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around.

NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.

19. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.

20. Wait at least an hour for the rear window to dry, then spray water over the window and check for leaks. Mark the leaking areas, and let the window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after window installation. If the vehicle has to used within the first 4 hours, it must be driven slowly.

21. Reinstall all remaining removed parts.

NOTE: Advise the customer not to do the following things for 2 to 3 days:

- Slam the doors with all the windows rolled up.
- Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).