Rear Window Replacement Pickup

Tools Required

1. Apply masking tape to the area around the window in order to protect the painted surfaces from damage and to protect the headliner.
2. Remove the rear window lower molding. Refer to Rear Window Lower Garnish Molding Replacement in Interior Trim.
3. Remove both rear seat headrests (extended cab). Refer to Rear Seat Head Restraint Replacement .




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. Using a sharp utility knife, make a preliminary cut around the perimeter of the rear window, cut as close to edge of the rear window as possible.




Important: Keep the cutting edge of the tool against the stationary window when removing 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.

5. Use J 24402-A or J 39032 in order to cut the window from the pinchweld flange. Do this from inside the vehicle in order to protect the outer paint surface.



6. With the aid of an assistant, use the suction cups in order to lift the rear window from the opening.
7. Remove the rear reveal molding from the edge of the window.
8. Inspect the following components for the causes of a broken rear window:

•	The flange of the rear window opening

•	The rear window reveal molding

•	The rear window

9. Inspect for any of the following problems in order to help prevent future breakage of the rear 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 necessary, refinish the pinchweld flange in order to present a clean primer only surface. If paint repairs are required, mask the flange bonding area prior to the application of the color coat in order to provide a clean primer only surface. Materials such as BASF DE17®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP 70 and Martin-Semour 5120 and 5130 products are approved for this application.

10. After repairing the opening as indicated, perform the following steps:
11. Inspect the condition of the rear window opening and the urethane adhesive bead in order to determine which installation method you will use. Refer to Short Method Description or Extended Method Description for the guidelines.

11.1.

Remove all traces of broken glass from the vehicle.

11.2.

Clean around the edge of the inside surface of the rear 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.

After repairing the opening as indicated, perform the following:

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 primed (black #3) to the surface of the bonding area.
3. Allow the primer to dry for approximately 10 minutes, Ensure that all nicks and scratches are cover.
4. If the rear window reveal molding is damaged by cutting it too close to the window surface, replace the window.

Install the rear window reveal molding to the edge of the window.

5. With the aid of an assistant, dry fit the rear window into the opening in order to determine the correct way to position the rear window in the opening.



6. Use masking tape in order to mark the location of the rear window in the opening.
7. Slit the masking tape at the top edge of the rear window.
8. With the aid of assistant and using suction cups remove the rear window from the opening.
9. Place the rear window inside up on a clean, protected surface.
10. If the original rear window is being reused, remove all but approximately 2 mm (3/64 in) of the existing urethane adhesive from the rear window surface, using a utility knife or razor blade scraper.
11. Clean around the edge of the inside surface of the rear window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

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

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




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

19. Use a new dauber in order to apply glass prep (clear #3) to the area approximately 10 mm to 6 mm (3/8 in to 5/8 in). around the entire perimeter of the window inner surface.
20. Apply a second coat of the glass prep number (clear #1) to the same area of the glass.
21. Wipe the glass primed area immediately with a clean lint free cloth.
22. Shake the glass primer (black #2) for at least one minute.



23. Use a new dauber in order to apply the glass primer (black #2) to the same areas that glass prep (clear #1) was applied.

The glass primer (black #2) is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.

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



25. If using the short method, of cut the tip of the nozzle to provide an adhesive bead of 6.0 mm (1/4 in ).
26. If using the extended method, 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.



27. Use a cartridge type caulking gun, to apply a smooth continuous bead of urethane adhesive.
28. If reusing the original glass apply the new urethane adhesive on the top of the fresh trimmed urethane adhesive.



29. When using the extended method, use the edge of them lift gate 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 lift gate window (3).
30. With the aid of an assistant, use the suction cups in order to install the lift gate window into the opening.
31. Align the tape on the rear window and the body.
32. Press the rear window firmly into place.
33. Tape the rear window to the body in order to minimize movement until the urethane adhesive cures.
34. Clean any excess urethane adhesive from the body.

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

35. Use a soft spray of water in order to watertest the rear window immediately.
36. Warm or hot water is preferred in order to accelerate the cure of adhesive.
37. Inspect the window for leaks:

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

38. Retest the window for leaks.
39. The following conditions must be maintained to properly cure the urethane:

39.1.

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

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.

39.2.

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

39.3.

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

39.4.

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

39.5.

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

39.6.

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

40. Install all trim panels which were removed in order to gain access for rear window removal. Refer to Rear Window Lower Garnish Molding Replacement in Interior Trim.
41. Install the headrests. Refer to Rear Seat Head Restraint Replacement .
42. Remove the protective coverings and tape from the vehicle rear and headliner.

Rear Window Replacement Utility w/Cargo Door

Tools Required

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. Disconnect the washer hose from the rear.
4. Apply masking tape to the area around the window in order to protect the painted surfaces from damage and to protect the headliner.
5. Open rear window.
6. Remove the rear window garnish molding refer to interior trim for removal. Refer to Rear Upper Garnish Molding Replacement .



7. Disconnect the electrical connector from the rear window defogger on the rear window.




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.

8. Using a sharp utility knife, make a preliminary cut around the perimeter of the rear window, cut as close to edge of the rear window as possible.




Important: Keep the cutting edge of the tool against the stationary window when removing 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.

9. Use J 24402-A or J 39032 in order to cut the window from the pinchweld flange. Do this from inside the vehicle in order to protect the outer paint surface.



10. With the aid of an assistant, use the suction cups in order to lift the rear window from the opening.
11. Remove the rear reveal molding from the edge of the window.
12. Inspect the following components for the causes of a broken rear window:

•	The flange of the rear window opening

•	The rear window reveal molding

•	The rear window

13. Inspect for any of the following problems in order to help prevent future breakage of the rear 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 necessary, refinish the pinchweld flange in order to present a clean primer only surface. If paint repairs are required, mask the flange bonding area prior to the application of the color coat in order to provide a clean primer only surface. Materials such as BASF DE17®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP 70 and Martin-Semour 5120 and 5130 products are approved for this application.

14. After repairing the opening as indicated, perform the following steps:
15. Inspect the condition of the rear window opening and the urethane adhesive bead in order to determine which installation method you will use. Refer to Short Method Description or Extended Method Description for the guidelines.

15.1.

Remove all traces of broken glass from the vehicle.

15.2.

Clean around the edge of the inside surface of the rear 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.

After repairing the opening as indicated, perform the following:

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 primed (black #3) to the surface of the bonding area.
3. Allow the primer to dry for approximately 10 minutes, Ensure that all nicks and scratches are cover.
4. If the rear window reveal molding is damaged by cutting it too close to the window surface, replace the window.

Install the rear window reveal molding to the edge of the window.

5. With the aid of an assistant, dry fit the rear window into the opening in order to determine the correct way to position the rear window in the opening.



6. Use masking tape in order to mark the location of the rear window in the opening.
7. Slit the masking tape at the top edge of the rear window.
8. With the aid of assistant and using suction cups remove the rear window from the opening.
9. Place the rear window inside up on a clean, protected surface.
10. If the original rear window is being reused, remove all but approximately 2 mm (3/64 in) of the existing urethane adhesive from the rear window surface, using a utility knife or razor blade scraper.
11. Clean around the edge of the inside surface of the rear window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

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

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




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

19. Use a new dauber in order to apply glass prep (clear #3) to the area approximately 10 mm to 6 mm (3/8 in to 5/8 in). around the entire perimeter of the window inner surface.
20. Apply a second coat of the glass prep number (clear #1) to the same area of the glass.
21. Wipe the glass primed area immediately with a clean lint free cloth.
22. Shake the glass primer (black #2) for at least one minute.



23. Use a new dauber in order to apply the glass primer (black #2) to the same areas that glass prep (clear #1) was applied.

The glass primer (black #2) is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.

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



25. If using the short method, of cut the tip of the nozzle to provide an adhesive bead of 6.0 mm (1/4 in ).
26. If using the extended method, 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.



27. Use a cartridge type caulking gun, to apply a smooth continuous bead of urethane adhesive.
28. If reusing the original glass apply the new urethane adhesive on the top of the fresh trimmed urethane adhesive.



29. When using the extended method, use the edge of them lift gate 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 lift gate window (3).
30. With the aid of an assistant, use the suction cups in order to install the lift gate window into the opening.
31. Align the tape on the rear window and the body.
32. Press the rear window firmly into place.
33. Tape the rear window to the body in order to minimize movement until the urethane adhesive cures.
34. Clean any excess urethane adhesive from the body.

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

35. Use a soft spray of water in order to watertest the rear window immediately.
36. Warm or hot water is preferred in order to accelerate the cure of adhesive.
37. Inspect the window for leaks:

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

38. Retest the window for leaks.
39. The following conditions must be maintained to properly cure the urethane:

39.1.

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

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.

39.2.

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

39.3.

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

39.4.

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

39.5.

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

39.6.

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




40. Connect the electrical connector from the rear window defogger on the rear window.
41. Install the rear window garnish molding refer to interior trim. Refer to Rear Upper Garnish Molding Replacement .
42. Close rear window.
43. Remove the protective coverings and tape from the vehicle rear window and headliner.