GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Avalanche - 4WD 🢒 Body and Accessories 🢒 Stationary Windows 🢒 Adhesive Installation of Stationary Windows
  1. Use a urethane adhesive systems which meet GM Specification GM 3651G

    2. 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.

  2. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
  3. If the original window is being reused, remove all but approximately 2 mm (3/64 in) of the existing bead of urethane adhesive from the pinch-weld flange surface by using a clean utility knife or razor blade scraper.
  4. Inspect for any of the following problems in order to help prevent future breakage of the window:
    5. • High weld
    • Solder spots on the pinch-weld
    • Hardened sealer
    • Any other obstruction or irregularity in the pinch-weld flange

    Important: If corrosion of the pinch-weld flange is present or if sheet metal repairs or replacements are required, the pinch-weld 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 DE15®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120 and 5130® PPG DP90LF SPIES/HECKER 3688/8590 - 3688/5150 - 4070/5090 STANDOX 11158/13320 - 14653/14980 products are approved for this application.

  5. After repairing the opening as indicated, perform the following steps:
    6. 5.1. Remove all traces of broken window from the outer cowl panel, seats, floor and defroster ducts.
    5.2. 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: 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.

  6. Verify all primers and urethane adhesive are within expiration dates.

    7. Object Number: 245283 Size: SH

    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.

    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.

    Important: Do not apply the black #3 primer to the existing bead (1) of the urethane adhesive on the pinch-weld flange. Apply the primer only to nicks, scratches or the primed surfaces.

  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 (2).
  9. Allow the pinch-weld primer to dry for approximately 10 minutes.

    10. Object Number: 441419 Size: SH
  10. With the aid of an assistant, dry fit the window (1) to the opening in order to determine the correct position.

    11. Object Number: 767126 Size: SH
  11. Position the locator pins on the window into the upper sheet metal slots in order to hold the window in place.

    12. Object Number: 745571 Size: SH
  12. Use masking tape in order to mark the locations (1) of the window (2) in the opening.
  13. Cut the masking tape in the center and remove the window from the opening.

    14. Object Number: 379890 Size: SH

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

  14. Use a new dauber in order to apply window prep clear #1 to the area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the window inner surface.

    15. Immediately wipe the window primed area using a clean, lint-free cloth.


    Object Number: 161424 Size: SH
  15. Apply a second coat of the window prep clear #1 to the same area of the window.

    16. Object Number: 245290 Size: SH

    Important: The window primer black #2 is effective up to 8 hours after applying it to the window. The primed surface of the window must be kept clean.

  16. Shake the window primer black #2 for at least 1 minute.
  17. Use a new dauber in order to apply the window primer black #2 to the same areas (2) that window prep clear #1 was applied.
  18. Allow the window primer to dry for approximately 10 minutes.

    19. Object Number: 161427 Size: SH
  19. Cut the applicator nozzle in order to provide a bead of 13 mm (1/2 in) wide and 13 mm (1/2 in) high.

    20. Object Number: 161429 Size: SH
  20. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.

    21. Object Number: 245315 Size: SH
  21. Use the edge of the window (3) as a guide for the nozzle in order to apply the urethane adhesive (2) to the inner surface of the window (3).

    22. Object Number: 745570 Size: SH

    Important:  If the locator pins were damage when removing it will be necessary to tape the window in place until chemical-curing for the type of urethane adhesive used.

  22. Place the window on the lower supports (2), if equipped with the aid of an assistant, place the window in the opening ensuring that the locator pins on the window align with the upper sheet metal slots in order to hold the window in place.

    23. Object Number: 745571 Size: SH
  23. Align the masking tape (1) lines on the window (2) and the body.

    24. Object Number: 706204 Size: SH
  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. Object Number: 706194 Size: SH
  26. Clean any excess urethane adhesive from the body.

    27. Object Number: 95572 Size: SH

    Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.

  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. 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.

  31. Maintain the following conditions in order to properly cure the urethane adhesive:
    32. • 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.