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Home/Chevrolet/Silverado 2500 HD/Chevrolet Silverado 2500 HD (2002-2012)/Repair manual/Heated Glass/defoggers/Fixed & Moveable Window Systems: Removal & Installation
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Fixed & Moveable Window Systems: Removal & Installation Chevrolet Silverado 2500 HD

Heated Glass/defoggers 26 illustrations ~3969 words

Windshield Replacement

Tools Required

  1. J 24402-A Glass Sealant Cold Knife Remover. See «Special Tools»(ref-278004-S09402871542008012100000) .
  2. J 39032 Stationary Window Removal Tool. See «Special Tools»(ref-278004-S09402871542008012100000) .
  3. Urethane Adhesive Kit GM P/N 12346392 or Equivalent
  4. Isopropyl Alcohol or Equivalent
  5. Cartridge-type Caulking Gun
  6. Commercial-type Utility Knife
  7. Razor Blade Scraper
  8. Suction Cups
  9. Plastic Paddle

Removal Procedure

  1. Remove the fixed antenna mast if equipped. Refer to «Fixed Antenna Replacement»(ref-277998-S14937671162008012100000) .
  2. Open the hood.
  3. Remove the window wiper arms. Refer to «Windshield Wiper Arm Replacement (LD)»(ref-278010-S01248116002008012100000) or «Windshield Wiper Arm Replacement (HD)»(ref-278010-S24706344672008012100000) .
  4. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-278010-S22815685882008012100000) .
  5. Remove the outside moisture sensor. Refer to «Windshield Outside Moisture Sensor Replacement»(ref-278010-S34351363082008012100000) .
  6. Remove the inside rearview mirror. Refer to «Inside Rearview Mirror Replacement»(ref-278022-S14377066282008012100000) .
  7. Reposition the front door sealing weatherstrips (1) in order to access the side reveal molding screws. You do not have to remove the front door sealing weatherstrip completely from the vehicle.
  8. Remove the screws from the left and the right sides of window side reveal moldings.
  9. Remove the reveal moldings from the vehicle.
  10. Cover the following parts to protect from broken glass: The upper dash pad The defroster outlets and A/C outlets The seats and the carpeting
  11. Remove the upper window reveal molding (1).
  12. Remove the window lower supports (1) by using a flat-bladed tool, lightly prying upward in the middle until the support releases.
  13. Use J 24402-A , J 39032 , or equivalent in order to remove the window. See «Special Tools»(ref-278004-S09402871542008012100000) . Leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.
  14. Remove the bottom of the window from the urethane adhesive using a long utility knife or similar tool.
  15. With the aid of an assistant remove the window (1) from the vehicle.

Installation Procedure

  1. Install a stationary window into the opening. Refer to «Adhesive Installation of Stationary Windows (Windshield)»(ref-278004-S07752033032008012100000) or «Adhesive Installation of Stationary Windows (Rear Window)»(ref-278004-S16411584172008012100000) .
  2. Install the window side reveal moldings to the vehicle.
  3. Install the screws to the left and the right sides of the window side reveal moldings. Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Install the front door sealing weatherstrips (1) to the retainer (2).
  5. Install the cowl air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-278010-S22815685882008012100000) .
  6. Install the window wiper arms. Refer to «Windshield Wiper Arm Replacement (LD)»(ref-278010-S01248116002008012100000) or «Windshield Wiper Arm Replacement (HD)»(ref-278010-S24706344672008012100000) .
  7. Install the antenna mast, if equipped. Refer to «Fixed Antenna Replacement»(ref-277998-S14937671162008012100000) .
  8. Install the outside moisture sensor. Refer to «Windshield Outside Moisture Sensor Replacement»(ref-278010-S34351363082008012100000) .
  9. Install the inside rearview mirror. Refer to «Inside Rearview Mirror Replacement»(ref-278022-S14377066282008012100000) .
  10. Close the hood.
  11. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim.
  1. Remove the windshield. Refer to «Windshield Replacement»(ref-278004-S21616069762008012100000) .
  2. Remove the upper reveal molding (1) from the windshield (2) starting at the center and working outboard to both ends.
  1. Install the upper reveal molding (1) to the windshield (2).
  2. Align the notch in the molding to the center mark on the upper paint band on the windshield.
  3. Press the upper reveal molding on to the windshield starting at the center and working outboard to both sides.
  4. Install the windshield. Refer to «Windshield Replacement»(ref-278004-S21616069762008012100000) .

Scheme 18

Scheme 18: Windshield Side Reveal Molding Replacement
Scheme 18: Windshield Side Reveal Molding Replacement
CalloutComponent Name
Preliminary Procedures Open the front door on the side the reveal molding is being serviced. Pull the door auxiliary weatherstrip up to the roof header. Remove the air inlet grille panel end cap.
1Reveal Molding Nuts
2Windshield Side Reveal Molding Tip: Upon installation, tuck the bottom edge of the reveal molding under the end cap of the air inlet grille panel prior to the screw installation.
3Windshield Side Reveal Molding Screws (Qty: 5) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
NOTE
Refer to Fastener Notice .

Windshield Side Reveal Molding Replacement

Scheme 19

Scheme 19: Front Side Door Window Replacement
Scheme 19: Front Side Door Window Replacement
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (YE9) or Front Side Door Trim Panel Replacement (SLT) . Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement . Remove the front side door inner belt sealing strip. Refer to Front Side Door Window Belt Inner Sealing Strip Replacement . Remove the front weatherstrip. Refer to Front Side Door Window Weatherstrip Replacement .
1Front Door Window Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Procedure: Loosen the 2 bolts that attach the window to the window regulator. Tighten: 10 N.m (89 lb in)
2Front Door Window Tip: The window must be tilted downward into the door to remove it.
NOTE
Refer to Fastener Notice .

Front Side Door Window Replacement

Scheme 20

Scheme 20: Rear Side Door Window Replacement (Crew Cab)
Scheme 20: Rear Side Door Window Replacement (Crew Cab)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) . Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement . Remove the rear door window weatherstrip. Refer to Rear Side Door Window Weatherstrip Replacement (Crew Cab) or Rear Side Door Window Weatherstrip Replacement (Extended Cab) .
1Rear Door Window Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Procedure: Loosen the 2 bolts that attach the window to the window regulator. Tighten: 7 N.m (61 lb in)
2Rear Door Window Tip: The window must be tilted downward into the door to remove it.
NOTE
Refer to Fastener Notice .

Rear Side Door Window Replacement (Crew Cab)

Scheme 21

Scheme 21: Rear Side Door Window Replacement (Extender Cab)
Scheme 21: Rear Side Door Window Replacement (Extender Cab)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) . Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement . Remove the rear door inner sealing strip. Refer to Rear Door Window Belt Inner Sealing Strip Replacement (Crew Cab) or Rear Door Window Belt Inner Sealing Strip Replacement (Extended Cab) . Remove the rear door window weatherstrip. Refer to Rear Side Door Window Weatherstrip Replacement (Crew Cab) or Rear Side Door Window Weatherstrip Replacement (Extended Cab) .
1Rear Door Window Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Procedure: Loosen the 2 bolts that attach the window to the window regulator. Tighten: 7 N.m (61 lb in)
2Rear Door Window Tip: The window must be tilted downward into the door to remove it.
NOTE
Refer to Fastener Notice .

Rear Side Door Window Replacement (Extender Cab)

  1. Place tape from body side to window to hold in place.
  2. Remove the side access door trim panel. Refer to «Rear Side Access Door Trim Panel Replacement»(ref-277987-S29277659652008012100000) .
  3. Disconnect the window latch.
  4. Remove the bolts from the hinges.
  5. Remove the tape and window from the vehicle.
  1. Position the window and tape into position.
  2. Install the bolts to the hinges. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the window latch.
  4. Remove the tape and inspect the window.
  5. Install the side access door trim panel. Refer to «Rear Side Access Door Trim Panel Replacement»(ref-277987-S29277659652008012100000) .

Rear Window Replacement

Tools Required

  1. J 24402-A Cold Knife Glass Sealant Remover. See «Special Tools»(ref-278004-S09402871542008012100000) .
  2. J 39040 Quarter Window Remover. See «Special Tools»(ref-278004-S09402871542008012100000) .
  3. Urethane Adhesive Kit GM P/N 12346392 or Equivalent
  4. Isopropyl Alcohol or Equivalent
  5. Cartridge-type Caulking Gun
  6. Commercial-type Utility Knife
  7. Razor Blade Scraper
  8. Suction Cups
  9. Plastic Paddle
  1. Remove the window lower garnish molding. Refer to «Rear Window Lower Garnish Molding Replacement (Regular Cab)»(ref-277987-S06614697192008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48)»(ref-277987-S02789156272008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48)»(ref-277987-S16045225122008012100000) .
  2. Remove both rear seat headrests (extended cab). Refer to «Head Restraint Replacement»(ref-277984-S08358550572008012100000) .
  3. Lower rear seat back.
  4. Remove the rear sliding window regulator, if equipped. Refer to «Rear Sliding Window Regulator Replacement»(ref-278004-S10867558242008012100000) .
  5. Cover to protect the following parts from broken glass: Upper dash pad Defroster outlets and A/C outlets Seats and carpeting
  6. 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. Use J 24402-A , J 39040 or equivalent in order to remove the window. See «Special Tools»(ref-278004-S09402871542008012100000) .
  7. Open the window, if equipped.
  8. With the aid of an assistant, remove the window from the opening.
  1. Install a stationary window into the opening. Refer to «Adhesive Installation of Stationary Windows (Windshield)»(ref-278004-S07752033032008012100000) or «Adhesive Installation of Stationary Windows (Rear Window)»(ref-278004-S16411584172008012100000) .
  2. Install the rear sliding window regulator, if equipped. Refer to «Rear Sliding Window Regulator Replacement»(ref-278004-S10867558242008012100000) .
  3. Install the window lower garnish molding. Refer to «Rear Window Lower Garnish Molding Replacement (Regular Cab)»(ref-277987-S06614697192008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48)»(ref-277987-S02789156272008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48)»(ref-277987-S16045225122008012100000) .
  4. Install both rear seat headrests (extended cab). Refer to «Head Restraint Replacement»(ref-277984-S08358550572008012100000) .
  5. Raise the rear seat back.
  6. Remove the double layer of masking tape around the perimeter of the painted surfaces and interior trim.
  1. Cycle the rear sliding window to the halfway position.
  2. Remove the rear lower garnish molding. Refer to «Rear Window Lower Garnish Molding Replacement (Regular Cab)»(ref-277987-S06614697192008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48)»(ref-277987-S02789156272008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48)»(ref-277987-S16045225122008012100000) .
  3. Remove the rear sliding window stops (1).
  4. Remove the rear sliding window pulley covers (2).
  5. Remove the regulator cables (2) from the retainers (1) located across the bottom edge of the window frame.
  6. Remove the screw (1) from regulator (2).
  7. Remove the regulator (2) from the motor/module.
  8. Remove the pulley (1) from the frame. Lift the end of the tabs (2) out of the window frame (3). Turn upward to release the pulley (1) from the frame (3).
  9. Remove the cable ends (1) from the window guide (2) at each end of the window.
  10. Remove the regulator (1) and cables (2) from the vehicle.
  11. Remove the rear sliding window catch screws (1), catch, gasket (2) and nuts (3).
  12. Slide the window all the way to the left (driver side).
  13. Release the window from the upper frame, by push downward on the window.
  14. Remove the rear sliding window (4) from the frame.
  1. Install the rear sliding window (4) to the frame.
  2. Align the window to the upper and lower frame, push down the window and then pull upward locking the window in the frame.
  3. Slide the window all the way to the right (passenger side).
  4. Install the rear sliding window catch screws (1), catch, gasket (2) and nuts (3). Tighten: Tighten the nuts to 3 N.m (27 lb in).
  5. Slide window by hand, back and forth in the window frame to ensure proper operation before installing the regulator to the motor.
  6. Install the window to the halfway position.
  7. Install the regulator (1) and cables (2) to vehicle.
  8. Install the cable ends (1) to the window guide (2) at each end of the window.
  9. Install the regulator (2) to the motor/module.
  10. Install the screw (1) to the motor/module. Tighten: Tighten nuts to 5 N.m (44 lb in).
  11. Install the rear sliding window pulley (1). Align the tabs (2) on the pulley (1) with the notch in the frame (3). Turn the pulley downward, locking the pulley into the frame (3).
  12. Install the regulator cables (2) to the retainers (1) across the bottom edge of the window frame.
  13. Install the rear sliding window pulley covers (2) to the pulley (3), clip the tabs (1) in place.
  14. Install the rear sliding window stops (1) until fully seated.
  15. Cycle the rear sliding window to the fully closed position.
  16. Install the lower garnish molding. Refer to «Rear Window Lower Garnish Molding Replacement (Regular Cab)»(ref-277987-S06614697192008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48)»(ref-277987-S02789156272008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48)»(ref-277987-S16045225122008012100000) .
  17. Inspect the rear sliding window for proper operation.
  18. Clean the window.
  1. Cycle the rear sliding window to the halfway position.
  2. Remove the rear lower garnish molding. Refer to «Rear Window Lower Garnish Molding Replacement (Regular Cab)»(ref-277987-S06614697192008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48)»(ref-277987-S02789156272008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48)»(ref-277987-S16045225122008012100000) .
  3. Remove the rear sliding window stops (1).
  4. Remove the rear sliding window pulley covers (2).
  5. Remove the regulator cables (2) from the retainers (1) located across the bottom edge of the window frame.
  6. Remove the screw (1) from regulator (2).
  7. Remove the regulator (2) from the motor/module.
  8. Remove the pulley (1) from the frame. Lift the end of the tabs (2) out of the window frame (3). Turn upward to release the pulley (1) from the frame (3).
  9. Remove the cable ends (1) from the window guide (2) at each end of the window.
  10. Remove the regulator (1) and cables (2) from the vehicle.
  1. Install the regulator (1) and cables (2) to vehicle.
  2. Install the cable ends (1) to the window guide (2) at each end of the window.
  3. Install the regulator (2) to the motor/module.
  4. Install the screw (1) to the motor/module. Tighten: Tighten nuts to 5 N.m (44 lb in).
  5. Install the rear sliding window pulley (1). Align the tabs (2) on the pulley (1) with the notch in the frame (3). Turn the pulley downward, locking the pulley into the frame (3).
  6. Install the regulator cables (2) to the retainers (1) across the bottom edge of the window frame.
  7. Install the rear sliding window pulley covers (2) to the pulley (3), clip the tabs (1) in place.
  8. Install the rear sliding window stops (1) in place and fully seated.
  9. Cycle the rear sliding window to the fully closed position.
  10. Install the lower garnish molding. Refer to «Rear Window Lower Garnish Molding Replacement (Regular Cab)»(ref-277987-S06614697192008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48)»(ref-277987-S02789156272008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48)»(ref-277987-S16045225122008012100000) .
  11. Inspect the rear sliding window for proper operation.
  12. Clean the window.
  1. Remove the rear sliding center window. Refer to «Rear Sliding Window Replacement»(ref-278004-S24016101232008012100000) .
  2. Remove the rear sliding window weatherstrip (1) from the frame (2).
  3. Clean around the edges the frame with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth. Remove all traces of the old weatherstrip.
  1. Install the bottom and top of the weatherstrip (1). Perform the following: Installing the weatherstrip (1), ensure that the single edge of the strip is located on the top and bottom. Install both bottom corners and top corners must be fitted tightly into the frame before pressing in place.
  2. Install the weatherstrip (1) to the frame. Perform the following: Installing the weatherstrip (1), ensure that the double edge of the weatherstrip is located on each side. Do one side at a time, remove the tape backing from the weatherstrip. Start in the center of the window frame, work the weatherstrip up and down the sides pressing in place.
  3. Install the rear sliding center window. Refer to «Rear Sliding Window Replacement»(ref-278004-S24016101232008012100000) .
  4. Inspect the rear sliding window for proper operation.
  5. Water test to ensure no leaks.
  1. Remove the rear sliding window lower garnish molding. Refer to «Rear Window Lower Garnish Molding Replacement (Regular Cab)»(ref-277987-S06614697192008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48)»(ref-277987-S02789156272008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48)»(ref-277987-S16045225122008012100000) .
  2. Cycle the rear sliding window to the fully closed position.
  3. Remove the screw (1) from the rear sliding window regulator and cables (2).
  4. Pull forward on the regulator and cables (2) to release it from the motor/module.
  5. Remove the rear sliding window motor/module nuts (2).
  6. Disconnect the rear sliding window electrical connectors from the motor/module and relays (1).
  7. Remove the rear sliding window motor/module assembly from the vehicle.
  1. Install the rear sliding window motor/module assembly to the vehicle.
  2. Connect the rear sliding window electrical connectors to the motor/module and relays (1).
  3. Install the rear sliding window motor/module nuts (2). Tighten: Tighten nut to 10 N.m (89 lb in).
  4. Install the rear sliding window regulator and cables (2) to the motor/module.
  5. Install the bolt (1) to the rear sliding window regulator and cables (2). Tighten: Tighten bolt to 11 N.m (97 lb in).
  6. Install the rear sliding window lower garnish molding. Refer to «Rear Window Lower Garnish Molding Replacement (Regular Cab)»(ref-277987-S06614697192008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48)»(ref-277987-S02789156272008012100000) or «Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48)»(ref-277987-S16045225122008012100000) .
  7. Inspect the rear sliding window for proper operation.

Scheme 22

Scheme 22: Door Window Regulator Handle Replacement
Scheme 22: Door Window Regulator Handle Replacement
CalloutComponent Name
1Side Door Window Regulator Handle Retainer Clip
2Side Door Window Regulator Handle Assembly Tip: Use the J 9886-01 Door Handle Clip Remover to remove the crank handle. See Special Tools .

Door Window Regulator Handle Replacement

  1. Lift up on the loose area of the reveal molding.
  2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth.
  1. Verify all primers and urethane adhesive are within expiration dates.
  2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window.
  3. Wipe the glass primed area immediately with a clean lint-free cloth.
  4. Shake the glass primer, black #2, for at least 1 minute.
  5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window.
  6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld.
  7. Reinstall the window reveal molding. Start from the loose area and hand-press the reveal molding into place over the edge of the window. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. The tape is to be removed after 6 hours.

Scheme 23

Scheme 23: Front Side Door Window & Rear Side Door Window Switch Replacement (with DL8 and without SLT)
Scheme 23: Front Side Door Window & Rear Side Door Window Switch Replacement (with DL8 and without SLT)
CalloutComponent Name
1Front Side Door Window Switch Bezel Refer to Front Door Switch Bezel Replacement .
2Front Side Door Window and Rear Side Door Window Switch Procedure: Use a small flat bladed tool to aid in the removal of the switch from the bezel.

Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT)

Scheme 24

Scheme 24: Rear Side Door Window Switch Replacement (Extended Cab)
Scheme 24: Rear Side Door Window Switch Replacement (Extended Cab)
CalloutComponent Name
1Rear Side Door Window Switch Assembly Tip: Gently push assembly toward rear of door. Lift front of assembly from armrest using a small flat tool. Disconnect electrical connectors.

Rear Side Door Window Switch Replacement (Extended Cab)

Scheme 25

Scheme 25: Rear Side Door Window Switch Replacement (Crew Cab)
Scheme 25: Rear Side Door Window Switch Replacement (Crew Cab)
CalloutComponent Name
1Rear Side Door Window Switch Retainer (Qty: 2)
2Rear Side Door Window Switch Assembly Tip: Disconnect electrical connectors.

Rear Side Door Window Switch Replacement (Crew Cab)

Scheme 26

Scheme 26: Front Side Door Window Regulator Replacement (Power)
Scheme 26: Front Side Door Window Regulator Replacement (Power)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (YE9) or Front Side Door Trim Panel Replacement (SLT) . Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement .
1Front Side Door Window Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Procedure Tape the window to the door frame to prevent it from moving. Loosen the 2 bolts that attach the window to the window regulator. Tighten: 9 N.m (80 lb in)
2Front Side Door Window Regulator Bolt (Qty: 3) Tighten: 9 N.m (80 lb in)
3Front Side Door Window Regulator Nut (Qty: 2) Tighten: 9 N.m (80 lb in)
4Front Side Door Window Regulator Procedure Disconnect the electrical connector. Transfer the power window motor to the new regulator. Refer to Front Side Door Window Regulator Motor Replacement .
NOTE
Refer to Fastener Notice .

Front Side Door Window Regulator Replacement (Power)

Scheme 27

Scheme 27: Front Side Door Window Regulator Motor Replacement
Scheme 27: Front Side Door Window Regulator Motor Replacement
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (YE9) or Front Side Door Trim Panel Replacement (SLT) . Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement .
1Front Side Door Window Regulator Bolt (Qty: 6) NOTE: Refer to Fastener Notice . Procedure: Disconnect the electrical connector. Tighten: 4.6 N.m (41 lb in)
2Front Side Door Window Regulator
3Front Side Door Window Regulator Motor Bolt (Qty: 3) Tighten: 9 N.m (80 lb in)
4Front Side Door Window Regulator Motor
NOTE
Refer to Fastener Notice .

Front Side Door Window Regulator Motor Replacement

Scheme 28

Scheme 28: Rear Side Door Window Regulator Replacement (Crew Cab, Manual)
Scheme 28: Rear Side Door Window Regulator Replacement (Crew Cab, Manual)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) . Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
1Rear Side Door Window Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Procedure Tape the window to the door frame to prevent it from moving. Loosen the 2 bolts that attach the window to the window regulator. Tighten: 9 N.m (80 lb in)
2Rear Side Door Window Regulator Bolt (Qty: 5) Tighten: 9 N.m (80 lb in)
3Rear Side Door Window Regulator
NOTE
Refer to Fastener Notice .

Rear Side Door Window Regulator Replacement (Crew Cab, Manual)

Scheme 29

Scheme 29: Rear Side Door Window Regulator Replacement (Crew Cab, Power)
Scheme 29: Rear Side Door Window Regulator Replacement (Crew Cab, Power)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) . Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
1Rear Side Door Window Regulator Bolt (Qty: 5) NOTE: Refer to Fastener Notice . Procedure Tape the window to the door frame to prevent it from moving. Loosen the 2 bolts that attach the window to the window regulator. Tighten: 9 N.m (80 lb in)
2Rear Side Door Window Regulator Procedure Disconnect the electrical connector. Transfer the power window motor to the new regulator. Refer to Rear Side Door Window Regulator Motor Replacement (Crew Cab) or Rear Side Door Window Regulator Motor Replacement (Extended Cab) .
NOTE
Refer to Fastener Notice .

Rear Side Door Window Regulator Replacement (Crew Cab, Power)

Scheme 30

Scheme 30: Rear Side Door Window Regulator Replacement (Extended Cab, Power)
Scheme 30: Rear Side Door Window Regulator Replacement (Extended Cab, Power)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) . Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
1Rear Side Door Window Regulator Bolt NOTE: Refer to Fastener Notice . Procedure Place the door window in the up position Tape the window to the door frame to prevent it from moving. Loosen the upper bolts that attach the window regulator to the inner door. Tighten: 9 N.m (80 lb in)
2Rear Side Door Window Regulator Nuts (Qty: 2) Tighten: 9 N.m (80 lb in)
3Rear Side Door Window Regulator Procedure Disconnect the electrical connector. Transfer the power window motor to the new regulator. Refer to Rear Side Door Window Regulator Motor Replacement (Crew Cab) or Rear Side Door Window Regulator Motor Replacement (Extended Cab) .
NOTE
Refer to Fastener Notice .

Rear Side Door Window Regulator Replacement (Extended Cab, Power)

Scheme 31

Scheme 31: Rear Side Door Window Regulator Motor Replacement (Crew Cab)
Scheme 31: Rear Side Door Window Regulator Motor Replacement (Crew Cab)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement (Crew Cab, Manual) or Rear Side Door Window Regulator Replacement (Crew Cab, Power) or Rear Side Door Window Regulator Replacement (Extended Cab, Power) .
1Rear Side Door Window Regulator Motor Bolt (Qty: 3) NOTE: Refer to Fastener Notice . Procedure: Disconnect the electrical connector. Tighten: 9 N.m (80 lb in)
2Rear Side Door Window Regulator Motor
NOTE
Refer to Fastener Notice .

Rear Side Door Window Regulator Motor Replacement (Crew Cab)

Scheme 32

Scheme 32: Rear Side Door Window Regulator Motor Replacement (Extended Cab)
Scheme 32: Rear Side Door Window Regulator Motor Replacement (Extended Cab)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement (Crew Cab, Manual) or Rear Side Door Window Regulator Replacement (Crew Cab, Power) or Rear Side Door Window Regulator Replacement (Extended Cab, Power) .
1Rear Side Door Window Regulator Motor Bolt (Qty :3) NOTE: Refer to Fastener Notice . Procedure: Disconnect the electrical connector. Tighten: 9 N.m (80 lb in)
2Rear Side Door Window Regulator Motor
NOTE
Refer to Fastener Notice .

Rear Side Door Window Regulator Motor Replacement (Extended Cab)

Scheme 33

Scheme 33: Front Side Door Window Outer Sealing Strip Replacement
Scheme 33: Front Side Door Window Outer Sealing Strip Replacement
CalloutComponent Name
Preliminary Procedure Position the door window as needed for service. Tape off the lower window frame to prevent damage to the door. Remove the outside mirror. Refer to Power Mirror Replacement .
1Front Side Door Outer Belt Sealing Strip Procedure Lifting upward on the sealing strip end in order to unhook it from the inside door flange. Install the sealing strip to the flange of the door and push downward until fully seated.

Front Side Door Window Outer Sealing Strip Replacement

Scheme 34

Scheme 34: Front Side Door Window Belt Inner Sealing Strip Replacement
Scheme 34: Front Side Door Window Belt Inner Sealing Strip Replacement
CalloutComponent Name
Preliminary Procedure: Remove the interior trim panel. Refer to Front Side Door Trim Panel Replacement (YE9) or Front Side Door Trim Panel Replacement (SLT) .
1Front Side Door Inner Belt Sealing Strip Procedure: Pull upward on the sealing strip to release it from the inside door flange.

Front Side Door Window Belt Inner Sealing Strip Replacement

Scheme 35

Scheme 35: Rear Door Window Belt Inner Sealing Strip Replacement (Crew Cab)
Scheme 35: Rear Door Window Belt Inner Sealing Strip Replacement (Crew Cab)
CalloutComponent Name
Preliminary Procedures: Remove the interior trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) .
1Rear Side Door Inner Belt Sealing Strip Procedure: Pull upward on the sealing strip to release it from the inside door flange.

Rear Door Window Belt Inner Sealing Strip Replacement (Crew Cab)

Scheme 36

Scheme 36: Rear Door Window Belt Inner Sealing Strip Replacement (Extended Cab)
Scheme 36: Rear Door Window Belt Inner Sealing Strip Replacement (Extended Cab)
CalloutComponent Name
Preliminary Procedures: Remove the interior trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) .
1Rear Side Door Inner Belt Sealing Strip Procedure: Pull upward on the sealing strip to release it from the inside door flange.

Rear Door Window Belt Inner Sealing Strip Replacement (Extended Cab)

Scheme 37

Scheme 37: Rear Door Window Belt Outer Sealing Strip Replacement (Crew Cab Except Cadillac)
Scheme 37: Rear Door Window Belt Outer Sealing Strip Replacement (Crew Cab Except Cadillac)
CalloutComponent Name
Preliminary Procedure Position the door window as needed for service. Tape off the lower window frame to prevent damage to the door. Remove the outside mirror. Refer to Power Mirror Replacement .
1Rear Door Outer Belt Sealing Strip Procedure Lifting upward on the sealing strip end in order to unhook it from the door flange. Install the sealing strip to the flange of the door and push downward until fully seated.

Rear Door Window Belt Outer Sealing Strip Replacement (Crew Cab Except Cadillac)

Scheme 38

Scheme 38: Rear Door Window Belt Outer Sealing Strip Replacement (Extended Cab)
Scheme 38: Rear Door Window Belt Outer Sealing Strip Replacement (Extended Cab)
CalloutComponent Name
Preliminary Procedure Position the door window as needed for service. Tape off the lower window frame to prevent damage to the door. Remove the outside mirror. Refer to Power Mirror Replacement .
1Rear Door Outer Belt Sealing Strip Procedure Lifting upward on the sealing strip end in order to unhook it from the door flange. Install the sealing strip to the flange of the door and push downward until fully seated.

Rear Door Window Belt Outer Sealing Strip Replacement (Extended Cab)

Scheme 39

Scheme 39: Front Side Door Window Weatherstrip Replacement
Scheme 39: Front Side Door Window Weatherstrip Replacement
CalloutComponent Name
Preliminary Procedures: Remove the front door window regulator. Refer to Front Side Door Window Regulator Replacement (Power) .
1Front Door Window Weatherstrip Bolt NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Front Door Window Weatherstrip Procedure: Apply tape to the molding to prevent scratches.
NOTE
Refer to Fastener Notice .

Front Side Door Window Weatherstrip Replacement

Scheme 40

Scheme 40: Rear Side Door Window Weatherstrip Replacement (Crew Cab)
Scheme 40: Rear Side Door Window Weatherstrip Replacement (Crew Cab)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) . Remove the rear door inner sealing strip. Refer to Rear Door Window Belt Inner Sealing Strip Replacement (Crew Cab) or Rear Door Window Belt Inner Sealing Strip Replacement (Extended Cab) .
1Rear Door Window Weatherstrip Procedure Use a plastic flat-bladed tool to assist in releasing the window weatherstrip from the door frame. Carefully pull the window weatherstrip from the door flange.

Rear Side Door Window Weatherstrip Replacement (Crew Cab)

Scheme 41

Scheme 41: Rear Side Door Window Weatherstrip Replacement (Extended Cab)
Scheme 41: Rear Side Door Window Weatherstrip Replacement (Extended Cab)
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9) or Rear Side Door Trim Panel Replacement (SLT) . Remove the rear door inner sealing strip. Refer to Rear Door Window Belt Inner Sealing Strip Replacement (Crew Cab) or Rear Door Window Belt Inner Sealing Strip Replacement (Extended Cab) .
1Rear Door Rear Window Weatherstrip Bolt NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb in)
2Rear Door Rear Window Weatherstrip Procedure: After the bolt has been removed from the weatherstrip, pull downward to release it from the door.
3Rear Door Front Window Weatherstrip Bolt Tighten: 10 N.m (89 lb in)
4Rear Door Front Window Weatherstrip Procedure: After the bolt has been removed from the weatherstrip, pull downward to release it from the door.
NOTE
Refer to Fastener Notice .

Rear Side Door Window Weatherstrip Replacement (Extended Cab)

Adhesive Installation of Stationary Windows (Windshield)

  1. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
  2. 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.
  3. Inspect the following components for the causes of a broken window: The flange of the window opening The window reveal molding
  4. Inspect for any of the following problems in order to help prevent future breakage of the window: High weld Solder spots on the pinchweld Hardened sealer Any other obstruction or irregularity in the pinch-weld flange
  5. After repairing the opening as indicated, perform the following steps: Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts. 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.
  6. Verify all primers and urethane adhesive are within expiration dates.
  7. Shake the pinch-weld primer black #3 for at least 1 minute.
  8. Use a new dauber in order to apply the primer to the surface of the pinch-weld flange (1).
  9. Allow the pinch-weld primer to dry for approximately 10 minutes.
  10. With the aid of an assistant, dry fit the window (1) to the opening in order to determine the correct position.
  11. Use masking tape in order to mark the locations (1) of the window (2) in the opening.
  12. Cut the masking tape in the center and remove the window from the opening.
  13. 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. Immediately wipe the glass primed area using a clean, lint-free cloth.
  14. Apply a second coat of the glass prep clear #1 to the same area of the glass.
  15. Shake the glass primer black #2 for at least 1 minute.
  16. 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.
  17. Allow the glass primer to dry for approximately 10 minutes.
  18. Cut the applicator nozzle in order to provide a bead of 8 mm (0.316 in) wide and 12.7 mm (1/2 in) high.
  19. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.
  20. Align the masking tape (1) lines on the window (2) and the body.
  21. Press the window firmly into place.
  22. Tape the window to the body in order to minimize movement until the urethane adhesive cures.
  23. Clean any excess urethane adhesive from the body.
  24. Use a soft spray of warm water in order to immediately water test the window.
  25. Inspect the window for leaks.
  26. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
  27. Retest the window for leaks.
  28. Maintain the following conditions in order to properly cure the urethane adhesive: Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures. Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times. Do not use compressed air in order to dry the urethane adhesive.
  29. Complete the window installation.

Adhesive Installation of Stationary Windows (Rear Window)

  1. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
  2. 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.
  3. Inspect the following components for the causes of a broken window: The flange of the window opening The window reveal molding
  4. Inspect for any of the following problems in order to help prevent future breakage of the window: High weld Solder spots on the pinchweld Hardened sealer Any other obstruction or irregularity in the pinch-weld flange
  5. After repairing the opening as indicated, perform the following steps: Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts. 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.
  6. Verify all primers and urethane adhesive are within expiration dates.
  7. Shake the pinch-weld primer black #3 for at least 1 minute.
  8. Use a new dauber in order to apply the primer to the surface of the pinch-weld flange (1).
  9. Allow the pinch-weld primer to dry for approximately 10 minutes.
  10. If installing a new window reveal molding, start in the center and work toward each end pressing firmly into place.
  11. With the aid of an assistant, dry fit the window to the opening in order to determine the correct position.
  12. Use masking tape in order to mark the locations of the window in the opening.
  13. Cut the masking tape in the center and remove the window from the opening.
  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. Immediately wipe the glass primed area using a clean, lint-free cloth.
  15. Apply a second coat of the glass prep clear #1 to the same area of the glass.
  16. Shake the glass primer black #2 for at least 1 minute.
  17. 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.
  18. Allow the glass primer to dry for approximately 10 minutes.
  19. 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.
  20. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.
  21. 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).
  22. With the aid of an assistant, place the window in the opening. If installing a rear window, place the rear window on the lower supports, if equipped.
  23. Align the masking tape lines on the window and the body.
  24. Press the window firmly into place.
  25. Tape the window to the body in order to minimize movement until the urethane adhesive cures.
  26. Clean any excess urethane adhesive from the body.
  27. Use a soft spray of warm water in order to immediately water test the window.
  28. Inspect the window for leaks.
  29. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
  30. Retest the window for leaks.
  31. Maintain the following conditions in order to properly cure the urethane adhesive: Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures. Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times. Do not use compressed air in order to dry the urethane adhesive.
  32. Complete the window installation.

Scheme 42

Scheme 42: Front Side Door Window Front Channel and Rear Channel Replacement
Scheme 42: Front Side Door Window Front Channel and Rear Channel Replacement
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (YE9) or Front Side Door Trim Panel Replacement (SLT) . Remove the water deflector. Refer to Front Side Door Water Deflector Replacement . Remove the front door inner sealing strip. Refer to Front Side Door Window Belt Inner Sealing Strip Replacement .
1Front Door Window Run Channel Lower Bolt NOTE: Refer to Fastener Notice . Tighten: 11 N.m (97 lb in)
2Front Door Window Run Channel
NOTE
Refer to Fastener Notice .

Front Side Door Window Front Channel and Rear Channel Replacement

Scheme 43

Scheme 43: Front Side Door Window Rear Channel Replacement
Scheme 43: Front Side Door Window Rear Channel Replacement
CalloutComponent Name
Preliminary Procedures Position the door window as needed for service. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (YE9) or Front Side Door Trim Panel Replacement (SLT) . Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
1Front Door Window Run Channel Rear Bolt NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb in)
2Front Door Window Rear Run Channel Tip: Raise the door window to the fully close position to gain access the run channel.
NOTE
Refer to Fastener Notice .

Front Side Door Window Rear Channel Replacement

Full-Cut Method Description

IMPORTANTIf corrosion of the pinch-weld flange is present, or if sheet metal repairs or replacements are required, refinish the pinch-weld flange 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. Appropriate materials for these primer applications are typically 2 component catalyzed products. Use materials such as BASF DE15®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120,5130®, PPG DP90LF SPIES/HECKER 3688/8590 - 3688/5150 - 4070/5090 STANDOX 11158/13320 - 14653/14980 products are approved for this application. Follow the manufacturer's directions for the mix, the application, and the drying times. After repairing the opening as indicated, shake the pinch-weld primer black #3 well. Using a new dauber, apply the primer to the primed surface of the flange in the bonding area. Allow the primer to dry for 10 minutes.

Use only the full cut method, also known in the field as full strip method, when installing windows.

This method includes the following

  1. The replacement of a majority of the urethane adhesive bead. Remove all but approximately 2 mm (3/64 in) of the existing bead of urethane adhesive from the pinch-weld flange.
  2. Apply pinch-weld primer to any exposed painted areas on the pinch-weld flange.

No mounds or loose pieces of urethane adhesive should remain on the pinch-weld flange. Do not remove all traces of urethane adhesive.

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