Body Side Window Replacement Utility

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.

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

1. Cover the defroster grille outlets as needed.
2. Remove the body side trim panels. Refer to Body Side Trim Panel Replacement in Interior Trim.
3. Remove the anchor bolt securing the rear seat belt assembly to the roof (2-door utility only).

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.

4. Use safety glasses and gloves.
5. Cut the 2 rivets securing the glass assembly (2-door utility only).

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

6. Use the J 24402-A or J 39032 in order to remove the stationary window. Do this from inside the vehicle to protect the outer surface of the paint.
7. With the aid of an assistant, use the suction cups in order to lift the stationary window from the opening.

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 stationary window:

•	The flange of the stationary window opening

•	The stationary window reveal molding

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

•

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 stationary window opening and the adhesive bead to determine which installation method should be used. Refer to Short Method Description short method or Extended Method Description extended method for 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 stationary window 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 stationary window 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 primed (black #3) to the surface of the bonding area on the body only.
7. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.



8. Install the reveal molding to the edge of the stationary window. If the original reveal molding is damaged it must be replaced, if equipped.
9. With the aid of an assistant install the stationary window into the opening.
10. Use masking tape in order to mark the location of the stationary window in the opening.
11. Slit the masking tape at the top edge of the stationary window.



12. With the aid of an assistant remove the stationary window from the opening.
13. Place the stationary window inside up on a clean, protected surface.

Important: Do not remove all traces of the adhesive. Remove all mounds or loose pieces of urethane adhesive .

14. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the existing bead of adhesive from the pinchweld flange.
15. Clean around the edge of the inside surface of the stationary window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

Important: Do not apply the (black #3) primer to the existing bead of the urethane adhesive. Apply the primer only to nicks, scratches or the primed surfaces.

16. Shake the pinchweld primer (black #3) for at least 1 minute.
17. Use a new dauber to apply the primer to the surface of the pinchweld flange.
18. Allow the glass primer to dry for approximately 10  minutes.




Important: Use care when applying the prep (clear #1) to the stationary window. This primer dries almost instantly and may stain the viewing area of the stationary window if not applied evenly.

19. If installing a new non encapsulated stationary window:

19.1.

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 stationary window inner surface.

19.2.

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

19.3.

Wipe the primed window area immediately with a clean lint free cloth.

19.4.

Shake the glass primer (black #2) for at least 1 minute.

20. If installing a new encapsulated stationary window:

Use a new dauber, in order to apply the stationary window prep (clear #1) to the area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the glass inner surface of the primer/bonding areas). The primer is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.

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



22. If using the short method, cut the tip of the applicator nozzle in order to provide a bead of 6.0 mm (1/4 in).



23. If using the extended method, cut the applicator nozzle in order to provide a bead 10.5 mm (0.14  in) wide and 10.5 mm (0.14 in) high.



24. Use a cartridge type caulking gun to apply a smooth, continuous bead of new urethane adhesive.
25. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.



26. When using the extended 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 urethane adhesive (1) to the inner surface of the stationary window (3).



27. With the aid of an assistant, use the suction cups in order to install the stationary window into the opening.
28. Align the tape on the stationary window and the body.
29. Press the stationary window firmly into place.
30. Tape the stationary window to the body in order to minimize movement.
31. Install 2 new rivets in order to secure the glass assembly to the sheet metal (2-door utility only).



32. 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.

33. Use a soft spray in order to water test the stationary window immediately.

Inspect the stationary window for leaks.

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

37.1.

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

37.2.

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

37.3.

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

38. Install 2 new rivets in order to secure the glass assembly to the sheet metal.
39. Install the rear seat belt anchor bolt to the roof (2-door utility only).
40. Install the body side trim panels. Refer to Body Side Trim Panel Replacement in Interior Trim.
41. Remove the protective coverings and tape from the vehicle and the headliner.

Body Side Window Replacement Pickup

Tools Required

J 34940 Rivet Gun

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.

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. Use safety glasses and gloves.



2. Carefully spread the handle retainer outward in order to release the latch pin from the latch.
3. Remove the latch pin from the latch.
4. Remove the seat belt retractor. Refer to Front Seat Belt Replacement in Seat Belts.
5. Open the door in order to access the rivets.
6. Drill out the rivets retaining the window assembly.
7. Thoroughly clean all metal particles that may have lodged inside the body panel.
8. Remove the window assembly from the vehicle.

1. Install the window assembly to the vehicle.
2. Using the J 34940 (or equivalent), install the rivets in order to retain the window assembly to the vehicle.
3. Install the seat belt retractor. Refer to Front Seat Belt Replacement in Seat Belts.
4. Install the latch pin.

Using a punch, carefully drive the pin into the latch.