2009 Dodge Charger

Windshield and back glass removal and replacement instructions
By Bob Beranek
May 25, 2009
AUTO

Sponsored by Extractor


© 2009 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 400 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org

Vehicle type: Four-door sedan

NAGS® numbers*: Windshield part numbers DW1571 and DW1660, rain sensor; back glass DB10916GTY  

Helpful tools or supplies: Universal molding for the windshield

Watch for: A clip system holds the A-pillar moldings in place. Either release the clips from the underside of the molding in a typical fashion, or force a stiff plastic tool between the molding and the pillar, and lift up.

*With permission from National Auto Glass Specifications. Call NAGS at 800/551-4012 or visit http://glass.mithcell.com/.

A. Windshield
Preparation

1. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. Note: Always wear eye and hand protection when working with glass. Make sure you have the right glass and moldings and that the urethane systems you are about to use are current. Windshield part numbers are DW1571 and DW1660.

 2. Drape the fender with a fender cover and tape up any vulnerable areas on the vehicle to protect against possible damage. Tape up the defroster vents to prevent debris from falling into the openings.

3. To remove the rearview mirror, loosen the 20T Torx in the base of the mirror and slide the mirror off the mirror pad.

4. If the vehicle is equipped with a rain sensor, remove it. Remove the decorative cover, release the mounting clips and remove the sensor from the lens. The glass comes with the bracket attached.

5. Remove the windshield-wiper nut covers.

6. Remove the windshield-wiper nuts using a 16-millimeter wrench or socket. Move the wiper arm in an up-and-down motion to break it loose from the post, or use a wiper-puller. Caution: Wipers can sometimes be hard to remove. To avoid stressing the post, use a wiper-puller. 

7. To remove the cowl panel, first release the two quarter-turn retainers in the corners. Remove the five push-in retainers along the front leading edge of the cowl, and remove the retainers from the base of the A pillar moldings and the cowl panel. Lift the cowl panel from the vehicle and set it in a safe place.  
           

 



8. A clip system holds the A-pillar moldings in place. Either release the clips from the underside of the molding in a typical fashion, or force a stiff plastic tool between the molding and the pillar, and lift up.

9. The top molding is a wraparound U-channel type. Remove by grasping and pulling it out. You can use a universal molding as a replacement. Note: Before beginning windshield removal, verify the new windshield is the correct one and the urethanes and primers are current. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers.

Removal
10. Make sure cutting blades are sufficiently sharp.

11. Before cutting out the windshield, remove contaminants from the glass and pinchweld to prevent contact with the urethane.

12. Use the cutting tools of your choice to remove the glass from the adhesive bead. If you use a power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts.

13. Take the windshield out of the opening using vacuum cups. Make sure the vacuum cups do not overlap a crack in the glass. Lift the glass and place it on a windshield stand or suitable workstation.

Installation
14. After cutting the windshield out, remove contaminants such as dirt, moisture and debris from the pinchweld. Clean the dashboard.

15. Dry fit the new glass to the opening. Mark your glass using a grease pencil or retention molding tape.

16. Place your vacuum cups on the new windshield in the appropriate location.

17. Set the windshield onto the old urethane.

18. With the windshield resting in the opening, make sure it is in the right spot.

19. Adjust both sides to the correct setting, marking the passenger side, then the driver side. Lift the glass and place it on a windshield stand or suitable workstation.

20. Follow the urethane manufacturer’s recommendations for installation.

21. Clean the inside of the windshield using a urethane manufacturer-recommended product. Do not touch the bonding area of the windshield after cleaning, prepping or priming it.

22. Wear powder-free Nitrile gloves to protect against harsh chemicals.

23. Re-attach the top molding to the glass edge.

24. Apply the glass prep and primer following the urethane manufacturer’s recommendations.

25. Using the tool of your choice, remove the original urethane bead, leaving 1-2 millimeters of existing urethane on the pinchweld. Make sure there are no contaminants and do not touch the pinchweld after prepping the area.

26. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer’s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

27. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

28. Lift the windshield from the windshield stand or workstation using vacuum cups. Set the windshield on the urethane at the mark you made during your dry fit. Lower the driver’s side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place.

29. The windshield is now ready to be decked. Press firmly to ensure a good seal.

30. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

31. Re-install the removed parts in reverse order.

32. Allow the urethane to cure according to the urethane manufacturer’s recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends could jeopardize the structural integrity of the vehicle and the safety of its passengers.

33. You have completed the removal and replacement of the windshield.

B. Back glass
Removal
1. Make sure you have the right glass. Back glass part number is DB10916GTY. The glass comes with the molding already attached.

2. Remove the interior garnish molding to expose the defroster connectors.

3. Disconnect the defroster connectors.

4. Use the cutting tools of your choice to remove the glass from the adhesive bead. If you use a power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts. If your goal is to salvage the part, you may need to re-attach the underside molding.

 Installation
5. After cutting the back glass out, remove contaminants such as dirt, moisture and debris from the pinchweld.

6. Dry fit the new glass to the opening. Mark your glass using a grease pencil or retention molding tape.

7. Place your vacuum cups on the new back glass in the appropriate location.

8. Set the back glass onto the old urethane.

9. With the back glass resting in the opening, make sure it is in the right spot.

10. Adjust both sides to the correct setting, marking the passenger side, then the driver side. Lift the glass and place it on a windshield stand or suitable workstation.

11. Follow the urethane manufacturer’s recommendations for installation.

12. Clean the inside of the back glass using a urethane manufacturer-recommended product. Do not touch the bonding area of the back glass after cleaning, prepping or priming it.

13. Wear powder-free Nitrile gloves to protect against harsh chemicals.

14.  Apply the glass prep and primer following the urethane manufacturer’s recommendations.

15. Using a pinchweld scraper, remove as much of the original urethane as the urethane manufacturer recommends. Before removing the old urethane, make sure there are no contaminants and do not touch the pinchweld after prepping the area.

16. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer’s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

17. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

18. Lift the back glass from the windshield stand or workstation using vacuum cups. Set the glass  on the urethane at the mark you made during your dry fit. Lower the driver’s side of the back glass onto the urethane and line it up with the dry-fit mark; it is now in place.

19. The back glass is now ready to be decked. Press firmly to ensure a good seal.

20. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the back glass. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

21. Re-install the removed parts in reverse order.

22. Connect the defroster wiring harness and ground.

23. Check operation of the back glass electrical systems.

24. Allow the urethane to cure according to the urethane manufacturer’s recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends could jeopardize the structural integrity of the vehicle and the safety of its passengers.

25. You have completed the removal and replacement of the back glass.

© 2009 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 400 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org.

 

 

The author is president of Automotive Glass Experts in Sun Prairie, Wis. Write him at bberanek@aol.com.