REMOVAL & INSTALLATION All Except the Spirit Hatchback and Eagle SX/4
These models use a butyl tape retention method for rear window glass installation. An electric hot knife, tool J-24709-01 or equivalent, is necessary for this procedure. Also, an assistant would be very helpful.
- Cover all adjacent areas, both exterior and interior.
- If equipped, remove the wiper arm.
- Remove all finish moldings around the glass.
- If equipped, disconnect the wires from the rear defogger and tape the ends to the glass.
Use extreme care to avoid and scratching or damage to the defogger grid!
- Using the hot knife, insert the blade under the edge of the glass. Cut the material as close as possible to the inside surface of the glass.
Clean the hot knife blade with steel wool while it is still warm.
- Slowly push the glass outward along the top with your feet until the butyl tape stretches 1-2 in. Have an assistant cut the tape with a scissors, completely around the glass. Use wood blocks to keep the glass from touching the adhesive as the tape is being cut, or it will immediately restick.
- When the glass is out, remove all traces of the butyl tape from the glass opening and ball it up to lift off any remaining deposits. Use 3M General Purpose Adhesive Cleaner, or equivalent, to clean up the area.
- Make sure that there is no molding- or metal-to-glass interference.
- Make sure that all molding clips are properly positioned and not broken.
- Repair any broken weld studs.
- The two rubber spacer blocks below the glass at the outer ends must be in position to prevent the glass from settling and breaking.
- Make sure that the anti-squeak protector is in position on the lower flange.
- Using spacer blocks, temporarily position the glass in the opening.
- Center the glass to achieve equal spacing all around.
- Using masking tape at the bottom center or at the rubber spacers, and extending it over the body panels, mark the glass-to-body position for permanent installation.
- Cut the tape just below the glass and remove the glass.
- Clean the pinchweld and glass thoroughly. It must be clean and dry.
- Apply a thin, uniform, 1 / 2 in. wide coat of butyl tape primer on both the pinchweld flange and the glass edge, and allow it to dry for 10 minutes.
- Apply butyl tape to the pinchweld flange, midway up the right side, flush with the edge of the flange.
If you're using a butyl tape kit with an integral sponge rubber filler, make sure that the filler is flush with the edge of the flange.
- Strip off the paper as the tape is applied. Cut the tape at 45° angles downward and to the outside, and butt the ends of the tape firmly to prevent leaks.
- Place the glass in the opening, aligning it exactly with the tape markers you previously made. Be exact! The primer will adhere to the butyl tape on contact!
- Firmly press the glass against the butyl tape with hand pressure.
- Carefully trim excess primer with a razor blade.
- Clean the glass and surrounding area with 3M General Purpose Adhesive Cleaner, or equivalent.
- Recheck the glass-to-butyl tape contact, applying additional hand pressure as needed. Dull spots indicate poor contact.
- Apply 3M Windshield Sealer, or equivalent, to any open spots.
- Install all previously removed parts.
Spirit Liftaback and Eagle SX/4
The rear window on these models is retained by a rubber channel.
- Cover all adjacent areas.
- Remove the wiper arm and motor.
- From inside, peel the rubber channel down while pushing outward on the glass.
If the rubber channel is bonded to the pinchweld, spray a generous amount of 3M Release Agent, or equivalent, between the rubber channel and body. Allow 2-3 minutes for the stuff to work.
- Once the glass has been pushed away from the upper flange area, pull the window assembly up and out of the lower flange area.
- Remove all sealer from the flange with 3M General Purpose Adhesive Cleaner, or equivalent.
- Install the rubber channel on the glass.
- Lubricate the rubber channel liberally with soapy water and position the assembly in the body opening.
- Using a small wood spatula, pry the rubber channel over the pinchweld flange while an assistant pushes inward on the glass.
- Apply 3M Windshield sealer, or equivalent, between the channel and glass using a hand applicator gun.
- Wipe off surplus sealer.
- Install the wiper motor and arm.