Stationary Glass: Removal & Installation Dodge Durango II

INSTALLATION

Note. The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers located on the cowl at the bottom of the windshield opening should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the windshield opening.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Before proceeding with the following repair procedure, review all warnings and cautions. (Refer to «WARNING»(ref-212845-S17195832252005122700000) )
2. Level old bead of windshield adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive.
3. Apply four new spacers (2) to the a-pillars and place them evenly apart at the top and bottom.
4. Install the lower spacer assemblies (1) into the slotted holes and verify proper installation by pulling to make sure they are locked on. NOTE: Lower spacers must be facing with the flat side upwards when installing into the slotted holes.
5. Position windshield (1) in center of windshield opening and resting on the side and lower spacers (2 & 3).
6. Adjust the lower spacers (3) as required, to obtain the specified roof gap tolerance by pushing on the side of the wedge and raising or lowering the glass as necessary. For roof gap specifications, refer to the table «ROOF GAP TOLERANCES»(ref-212845-S37898130912005122700000) . Roof Gap Tolerances ROOF GAP TOLERANCES Roof Gap Roof Flush 4.0 mm +/- 1.5 mm Parallel within 2.0 mm Underflush 2.0 mm +/- 1.5 mm (0.16 in +/- 0.060 in) Parallel within (0.080 in) (0.080 in +/- 0.060 in)
7. Apply adhesive tape (1) to the locations shown to aid with final installation.
8. Verify windshield gap is parallel to with windshield.
9. Cut tape with a sharp knife and remove windshield. NOTE: Typical primer installation shown.
10. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag.
11. Using a flash light, verify that glass primer is without damage.
12. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed.
13. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2).
14. Allow primer to air dry for at least 10 minutes.
15. Using a flash light, verify that glass primer is without damage.

Scheme 9

Scheme 10

Scheme 11

1. Apply four new spacers (2) to the a-pillars and place them evenly apart at the top and bottom.
2. Install the lower spacer assemblies (1) into the slotted holes and verify proper installation by pulling to make sure they are locked on. NOTE: Lower spacers must be facing with the flat side upwards when installing into the slotted holes.
3. Position windshield (1) in center of windshield opening and resting on the side and lower spacers (2 & 3).
4. Adjust the lower spacers (3) as required, to obtain the specified roof gap tolerance by pushing on the side of the wedge and raising or lowering the glass as necessary. For roof gap specifications, refer to the table «ROOF GAP TOLERANCES»(ref-212845-S32357065452005122700000) . Roof Gap Tolerances ROOF GAP TOLERANCES Roof Gap Roof Flush 4.0 mm +/- 1.5 mm Parallel within 2.0 mm Underflush 2.0 mm +/- 1.5 mm (0.16 in +/- 0.060 in) Parallel within (0.080 in) (0.080 in +/- 0.060 in)
5. Clean and check windshield for damage.
6. Position windshield in center of windshield opening.
7. Apply adhesive tape to the locations shown to aid with final installation.
8. Verify windshield gap is parallel to with windshield.
9. Cut tape with a sharp knife and remove windshield.
10. Clean and dry area of glass to be glued with a suitable glass preparation solvent and rag.
11. Apply primer to gluing surface at windshield seal.
12. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2).
13. Allow primer to air dry for at least 10 minutes.
14. Using a flash light, verify that glass primer is without damage.

Scheme 12

Scheme 13

1. Clean and vacuum windshield opening.
2. Level old bead of windshield opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive.
3. Clean and dry area of windshield opening to be re-glued with a suitable glass preparation solvent and rag.
4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed.
5. Allow primer to air dry for at least 10 minutes.

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Apply bead of adhesive (1) with a triangular nozzle directly to the windshield seal starting at bottom in center of windshield. CAUTION: Always apply bead of adhesive to the windshield. Always install the windshield within 5 minutes after applying adhesive.
2. Bead dimensions should be approximately 9.5 - 12.0 mm wide (1) by 12.7 - 14.0 mm in height (2).
3. Allow end of adhesive bead to run out parallel to the start of the bead and smooth ends flush.
4. Lift windshield into place in the center of the windshield opening and use the tape as a guide to aid installation of the windshield into the center of the cutout.
5. Carefully lay down windshield and press on. CAUTION: It is no longer possible to move the windshield after installation. The windshield should never be pressed into place by more than one person, because the windshield can break if pressed simultaneously on both sides. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result.
6. Install cowl grille. (Refer to «PANEL-COWL TOP»(ref-212840-S21455115222005122700000) )
7. Install rear view mirror. (Refer to «MIRROR-INSIDE REARVIEW»(ref-212842-S32827587692005122700000) )

Note. The quarter glass fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected.

Scheme 18

Scheme 19

Scheme 20

1. Before proceeding with the following repair procedure, review all warnings and cautions. (Refer to «WARNING»(ref-212845-S17195832252005122700000) )
2. Level old bead of quarter glass adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. NOTE: Typical primer installation shown.
3. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag.
4. Using a flash light, verify that glass primer is without damage.
5. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed.
6. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (3).
7. Allow primer to air dry for at least 10 minutes.
8. Using a flash light, verify that glass primer is without damage.

REMOVAL

Note. Windshield removal shown, backlite similar.

Scheme 21

1. Before proceeding with the following repair procedure, review all warnings and cautions. (Refer to «WARNING»(ref-212845-S17195832252005122700000) )
2. Remove liftgate trim panels. (Refer to «PANEL-TRIM»(ref-212839-S38942888412005122700000) )
3. Remove the center stop light. (Refer to «LAMP-HIGH MOUNTED STOP»(ref-212790-S27073060082005122700000) )
4. Remove rear window wiper arm, if equipped. (Refer to «ARM-LIFTGATE WIPER»(ref-212808-S22080432142005122700000) )
5. Disconnect the heated backlite electrical connectors, if equipped.
6. Using a windshield cut-out wire or other suitable tool, separate the adhesive.
7. Carefully remove backlite.

Note. The backlite fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the lift-gate opening.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

1. Before proceeding with the following repair procedure, review all warnings and cautions. (Refer to «WARNING»(ref-212845-S17195832252005122700000) )
2. Level old bead of backlite adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive.
3. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge.
4. Install the lower spacers (2) to the backlite approximately 36 cm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass.
5. Position backlite in center of liftgate opening and resting on the side and lower spacers.
6. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar.
7. Verify the backlite gap is parallel to with the liftgate opening.
8. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown.
9. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag.
10. Using a flash light, verify that glass primer is without damage.
11. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed.
12. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2).
13. Allow primer to air dry for at least 10 minutes.
14. Using a flash light, verify that glass primer is without damage.

Scheme 27

Scheme 28

Scheme 29

Scheme 30

1. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge.
2. Install the lower spacers (2) to the backlite approximately 36 cm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass.
3. Position backlite in center of liftgate opening and resting on the side and lower spacers.
4. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar.
5. Verify the backlite gap is parallel to with the liftgate opening.
6. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown.
7. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag.
8. Apply primer to gluing surface at backlite seal.
9. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2).
10. Allow primer to air dry for at least 10 minutes.
11. Using a flash light, verify that glass primer is without damage.