Rear Window Replacement Utlity W/Cargo Door

Tools Required

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.

1. Unclip the defogger connector at the left and right side of the window from the inside of the cab, if equipped.
2. Remove all trim panels necessary in order to gain access for rear window removal.



3. Use the J 39032 from the inside of the window and J 24402-A from outside cut the adhesive (2) and remove the glass assembly from the window frame.
4. With an assistant standing outside of the vehicle, carefully push the window out from the vehicle.
5. The stationary window reveal molding retains the urethane adhesive in the cavity between the body and the opening. If the stationary window reveal molding is damaged by cutting it too close to the window surface, replace the window.
6. Inspect the condition of the stationary window opening and the urethane adhesive bead to determine which installation method should be used. Refer to Short Method Description or Extended Method Description for guidelines.

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 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. Materials such as BASF DE17 ®, DuPont 2610 ® and PPG DP40 ®, or equivalent products are approved for this application.

7. After repairing the opening as indicated, perform the following steps:

7.1.	Shake the pinchweld primer (#3 black) well.





7.2.	Use a new dauber to apply the primer to any exposed painted surfaces (or any scratches in the metal) of the flange in the bonding area.

7.3.	Allow the primer to dry for approximately 10 minutes.

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.

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.

1. With the aid of an assistant, dry fit the stationary window in the opening in order to determine the correct way to position the stationary window in the opening.



2. Use masking tape in order to mark the location of the stationary window in the opening.
3. Slit the masking tape at the top edge of the stationary window.
4. Remove the stationary window from the opening.
5. Place the stationary window inside up on a clean, protected surface.
6. If the original window is being reused, remove all but a thin film of the existing urethane adhesive from the window surface using a utility knife or equivalent.

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.

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.

7. Clean the inside surface of the stationary window with GM Glass Cleaner P/N 1050427 or equivalent.
8. If an extended method installation is being performed:

8.1.	Remove all but a thin film of the existing bead of adhesive from the pinchweld flange.

8.2.	It is not necessary to remove all traces of adhesive, but there should not be any mounds or loose pieces left.

Important: Use care when applying the stationary window prep (#1 clear) in order to prevent the stationary window prep from running into the vision area of the stationary window. This primer dries almost instantly and may stain the viewing area of the stationary window.

8.3.	Shake the pinchweld primer (#3 black) well.

8.4.	Use a new dauber to apply the primer to the primed surface of the flange in the bonding area.

8.5.	Allow the primer to dry for approximately 10 minutes.




9. If installing a new window:

9.1.	Use a new dauber, to apply the stationary window prep (#1 clear) approximately 10 mm to 16 mm (3/8 in to 5/8 in) around the entire perimeter of the glass inner surface (reference the illustration of the primer/bonding areas).

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

9.3.	Wipe the primed area immediately with a lint free cloth.




10. Shake the stationary window primer (#2 black) well.

10.1.

Use a new dauber, to apply the stationary window primer (#2 black) to the areas of the stationary window (1) which prep (#1 clear) was applied.

10.2.

Allow the primer to dry for approximately 6 minutes.




11. Cut the tip of the applicator nozzle as follows:

11.1.

If short method installation is being used, cut the tip to provide an urethane adhesive bead of approximately 6.0 mm (1/4 in).

11.2.

If extended installation method is being used, cut the tip to provide an adhesive bead of approximately 10.5 mm (0.14 in) wide and 10.5 mm  (0.14 in) high.




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



14. When using the extended installation 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 (2) urethane adhesive to the inner surface of the (3) stationary window.
15. Use rubber suction cups, and with the aid of a assistant, install the stationary window into the opening.
16. Align the tape on the stationary window and the body.
17. Press the stationary window firmly into place.
18. Tape the stationary window to body in order to minimize movement.

18.1.

Remove any excess urethane adhesive that may have squeezed out from the body.

18.2.

Use a soft spray of water in order to watertest the stationary window immediately.

18.3.

Warm or hot water is preferred in order to accelerate the cure of adhesive.

18.4.

Do not direct a hard stream of high pressure water at fresh urethane adhesive.

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.

Caution: At least 24 hours are required for complete curing of repair material. The repair area should not be physically distrubed until after that time. Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

Important: Inspect the stationary window for leaks.

19. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
20. Retest stationary window for leaks.
21. In order to properly cure the urethane adhesive, do the following:

•	Allow the vehicle to remain at room temperature of 22°C(72°  F) at 30 percent or less relative humidity.

•	Allow a minimum of (6 hours) for the moisture curing urethane adhesive.

•	Allow a minimum of (1 to 11/2 hours) for the chemical curing urethane adhesive.

•	Partially lower a door window to prevent pressure build ups when closing doors prior to urethane adhesive cure.

•	Do not drive the vehicle until the urethane adhesive is cured.

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

22. Remove the tape from the painted surfaces.
23. Connect the defogger clips on each side of the window on the inside to the body connectors, if equipped.
24. Install all trim panels which were removed in order to gain access for rear window removal.

Rear Window Replacement Pickup

Tools Required

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: The following components may reveal the causes of a broken window:

1. Unclip the defogger connector at the left and right side of the window from the inside of the cab, if equipped.
2. Remove all trim panels necessary in order to gain access for rear window removal.



3. Use the J 39032 to remove the glass assembly from the window frame.
4. With an assistant standing outside of the vehicle, push the window out from the vehicle.

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: Do not use the J 24402-A if the glass is not broken and is going to be reused as the molding may be damaged.

Important: The stationary window reveal molding retains the urethane adhesive in the cavity between the body and the opening. If the stationary window reveal molding is damaged by cutting it too close to the window surface, replace the window.

5. If the glass is already broken, theJ 24402-A may be used to remove the window.

Important: Keep the cutting edge of the tool against the window when removing. This will allow the urethane adhesive to be separated from the window and 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 cut the window from the pinchweld flange. Do this from inside the vehicle to protect the outer surface of the paint.
7. With an assistant standing outside of the vehicle, push the window out from the vehicle.
8. Look for any of the following problems in order to help prevent future breakage of the 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.

9. Using 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.
10. Inspect the condition of the stationary window opening and the urethane adhesive bead to determine which installation method should be used. Refer to Short Method Description or Extended Method Description extended method for guidelines.
11. Remove no more of the urethane adhesive than necessary in order to maintain the original shape. This will ensure the proper clearance between the window and the pinchweld flange.
12. After repairing the open as indicated, perform the following steps:

12.1.

Remove no more of the urethane adhesive form the pinchweld than necessary in order to maintain the original shape. This will ensure the proper clearance between the window and the pinchweld flange.

12.2.

Remove all traces of broken glass from the vehicle.

12.3.

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.

After repairing the opening as indicated, perform the following:

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.

1. Shake the pinchweld primer (black #3) for at least one 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.




2. Use a new dauber to apply the pinchweld primer (black #3) to the surface of the bonding area.
3. Allow the primer to dry for approximately 10 minutes, also check to ensure that all nicks and scratches are covered.
4. With the aid of an assistant, dry fit the stationary window into the opening.
5. Use masking tape in order to mark the location of the stationary window in the opening.
6. Slit the masking tape at the top edge of the stationary window.



7. Remove the stationary window from the opening.
8. Place the stationary window inside up on a clean, protected surface.
9. If the original window is being reused, remove all but a thin film of the existing urethane adhesive from the window surface using a utility knife or razor blade scraper.
10. 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.

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.

11. 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.

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

12. Shake the pinchweld primer (black #3) for at least one minute.
13. Use a new dauber to apply the primer to the surface of the pinchweld flange.
14. Allow the glass primer to dry for approximately 10  minutes.

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.





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

15. If installing a new non encapsulated window:

14.1.

Use a new dauber, to apply the stationary window prep (clear #3) approximately 10 mm to 16 mm (3/8 in to 5/8 in). around the entire perimeter of the window inner surface.

14.2.

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

14.3.

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

14.4.

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

14.5.

If installing a new encapsulated window:

Use a new dauber, in order to apply the window prep (clear #2) to the area approximately 10 mm to 16 mm (3/8 in to 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.

14.6.

Allow the glass primer to dry for approximately 10 minutes.




16. 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).



17. 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.



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



20. 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 (2) urethane adhesive to the inner surface of the (3) stationary window.
21. Use suction cups and, with the aid of an assistant, install the stationary window into the opening.



22. Align the tape on the stationary window and the body.
23. Press the stationary window firmly into place.
24. Tape the stationary window to the body in order to minimize movement.

23.1.

Clean any excess urethane adhesive from the body.

23.2.

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

23.3.

Using warm water is preferred in order to accelerate the cure of adhesive.

23.4.

Do not direct a hard stream of high pressure water at fresh urethane adhesive.

25. Inspect the stationary window for leaks.
26. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
27. Retest stationary window for leaks.

Caution: At least 24 hours are required for complete curing of repair material. The repair area should not be physically distrubed until after that time. Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

28. The following conditions must be maintained to properly cure the urethane.

27.1.

Allow the vehicle to remain at room temperature (21°C or 70°F) at 30 percent relative humidity.

27.2.

Allow a minimum of 6 hours for the moisture curing urethane adhesive.

27.3.

Allow a minimum of 1 hour to 1 1/2 hours for the chemical curing urethane adhesive.

27.4.

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

27.5.

Do not drive the vehicle until the urethane adhesive is fully cured.

27.6.

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

29. Remove the tape from the painted surfaces.

28.1.

Use a soft spray of water in order to watertest the stationary window immediately.

28.2.

Warm or hot water is preferred in order to accelerate the cure of adhesive.

28.3.

Do not direct a hard stream of high pressure water at fresh urethane adhesive.

Important: Inspect the stationary window for leaks.

30. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.

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.

Caution: At least 24 hours are required for complete curing of repair material. The repair area should not be physically distrubed until after that time. Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

31. Retest stationary window for leaks.
32. In order to properly cure the urethane adhesive, do the following:

•	Allow the vehicle to remain at room temperature of 22°C (72°F) at 30 percent or less relative humidity.

•	Allow a minimum of 6 hours for the moisture curing urethane adhesive.

•	Allow a minimum of 1 to 1 1/2 hours for the chemical curing urethane adhesive.

•	Partially lower a door window to prevent pressure build ups when closing doors prior to urethane adhesive cure.

•	Do not drive the vehicle until the urethane adhesive is cured.

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

33. Remove the tape from the painted surfaces.
34. Connect the defogger clips on each side of the window on the inside to the body connectors, if equipped.
35. Install all trim panels which were removed in order to gain access for rear window removal.
36. Remove the protective coverings and tape from the vehicle.