Chrysler Full-Size Trucks 1989-1996 Repair Guide

Windshield

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REMOVAL & INSTALLATION



1989-93 Dakotas

See Figure 1

The windshield is bonded to the cab pinch weld flanges with urethane adhesive. Glass removal is accomplished with a razor knife and an electric hot knife to cut through the urethane. Make sure an even, uniform bead of adhesive remains on the pinch weld flange during removal, as a base for the replacement glass.

The removal and installation of the windshield must be done carefully, improper installation can cause the windshield to crack or shatter. An assistant must be used to insure that the windshield is positioned properly in the opening.

  1. Cover the adjacent interior and exterior surfaces to avoid paint damage and extra clean-up time.
  2.  



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Fig. Fig. 1: Install the windshield as shown-Dakota models

  1. Remove the windshield wiper arms, reveal moldings, interior trim moldings, and the rearview mirror.
  2.  
  3. Make a preliminary cut around the perimeter with the razor knife. The purpose is of the cut is to expose the urethane away from the edge of the glass to expose the urethane between the glass and the flange.
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  5. Clean and sharpen the blade of the hot knife, if necessary.
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  7. Start the hot knife between the glass and adhesive. Next cut the adhesive as close to the glass edge as possible. Allow as much adhesive to remain on the pinch weld flange as possible. For best results, clean the knife blade frequently with steel wool while the blade is hot.
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CAUTION

Take care not to touch the hot blade to your skin, or a burn could result.

  1. Remove the windshield glass from the cab opening. Clean the hot knife with solvent after it has cooled.
  2.  

To install:
  1. Apply clear glass primer in a 1 in. (25mm) path around the perimeter of the windshield and wipe with a clean cloth. Allow at least 18 minutes drying time.
  2.  
  3. Inspect the urethane bead for high spots. Level the bead by shaving off the high spots with a razor knife. This is important for a flush fit.
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  5. Inspect the reveal molding. Replace if it is broken, distorted, or otherwise damaged.
  6.  
  7. Clean the outer edge of the windshield glass with naptha or a similar product. Wipe clean with a cheese cloth.
  8.  

CAUTION

Clean the windshield in a well-ventilated area only.

  1. Prime the outer perimeter of the interior side of the glass 5 / 8 in. (16mm) from the edge. Use a wipe-off type urethane primer and wipe the glass dry with a cheesecloth after the primer application.
  2.  
  3. Install two support spacers at the bottom of the windshield glass opening on the weld studs.
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  5. Install two spacers on each side and two more spacers at the top of the windshield glass opening.
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  7. Place the windshield glass on the cab pinch weld flanges and inspect for gaps in the urethane adhesive. Gaps bigger than 1 / 8 in. (3mm) must be filled with additional urethane adhesive.
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  9. Adjust the windshield glass position until it is aligned with the flanges and the adhesive. Make alignments marks on the glass and the body with a grease pencil or masking tape to use for an installation alignment reference.
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  11. Remove the windshield glass, but not the spacers, and place it on a flat surface.
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  13. If the replacement windshield does not have blackout primer, attach a 1 in. (25mm) wide band of masking tape around the interior side of the glass 3 / 8 in. (9.5mm) from the edge of the glass. Do not attach tape to the bottom of the glass, only on the inside. Clean the 3 / 8 in. (9.5mm) wide surface area around the glass with isopropyl alcohol. Thoroughly mix and apply glass blackout primer to the surface on the interior side. Allow the primer to dry for at least 10-12 minutes.
  14.  
  15. Apply a continuous 3 / 8 in. (9.5mm) bead of urethane adhesive to the surface area with the blackout primer on the interior side of the glass. Be prepared to install the windshield immediately after applying the adhesive. The adhesive begins to cure in about 10-15 minutes.
  16.  
  17. Align the glass with a grease pencil or tape reference marks and position the glass on the pinch weld flanges. Make sure the glass is correctly seated on the lower support spacers.
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  19. Force the windshield in just enough to wet-out and set the adhesive. Use caution to avoid excessive squeeze-out of the adhesive.
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  21. After the installation, water test the windshield with cold water. Do not spray direct blasts of water at the urethane adhesive. Use moderate spray only. If any leaks are detected, apply additional urethane adhesive as necessary.
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  23. Install the windshield reveal molding and remove the masking tape, if used, from the inside of the glass.
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  25. Install all other removed components and clean the vehicle.
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WARNING
If the interior is not vented, pressure build-up from the curing urethane could prevent proper windshield bonding.

  1. Open the vehicle windows to prevent interior pressure build-up while the urethane is curing.
  2.  

1989-93 Pick-Ups and Ramchargers

See Figures 2 and 3

  1. Cover the cowl to protect the paint.
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  3. Remove the wiper arms.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Details of a common windshield and weatherstripping

  1. Remove the windshield retainer strip from the weatherstripping. To remove the strip, pry up one end and carefully pull it out. Later models have a bright cap over the retainer which must be pried out first.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: With the help of an assistant, carefully lift the windshield away and remove it from the vehicle

  1. Have a helper support the windshield from the outside while you push one corner of the glass out of the weatherstripping.
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  3. Once one corner is free, continue pushing carefully around the glass until the entire windshield is free.
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  5. The weatherstripping can then be removed from the frame. Replace any defective weatherstripping.
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To install:

Use only mineral spirits as a lubricant when installing the windshield!

  1. Install the weatherstripping in the frame. Make sure it's completely seated.
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  3. With your helper's assistance, slide one corner of the glass into the lower groove in the weatherstripping.
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  5. Move the glass into the groove as far as possible.
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  7. Using a fiberglass spatula, force the lip of the weatherstripping over the glass, working around the entire circumference.
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  9. Starting at one of the lower corners, force the retaining strip into its groove in the weatherstripping. DON'T stretch the strip when installing it!
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  11. On later models, install the bright cap.
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  13. Using a hose, water test the windshield.
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  15. Install the wiper arms, then uncover the cowl.
  16.  

1994-96 Dakotas and Pick-Ups

See Figures 4, 5 and 6

The removal and installation of the windshield must be done carefully, improper installation can cause the windshield to crack or shatter. An assistant must be used to insure that the windshield is positioned properly in the opening.

  1. Remove the inside rearview mirror.
  2.  
  3. Remove the cowl cover and the windshield moldings. The moldings can be removed by pulling them upward.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Cut the urethane around the windshield

You should have windshield soft spacers, part No. 55028214, or equivalent, on hand prior to the installation procedure.

  1. Cut the urethane bonding from around the windshield using a sharp knife. Separate the windshield from the vehicle.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Center the windshield at the support spacers

To install:

Allow at least 24 hours for the urethane to cure before returning the vehicle to use. Support spacers should be cleaned and properly installed on weld studs or repair screws at the bottom of the windshield opening.

  1. Clean the windshield area of old urethane bonding that may be loose. Clean the support spacers and reposition them on the studs.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Have a clean work space set up in advance for working on the replacement glass

  1. With the aid of a helper, place the replacement windshield in the opening and position it in the center of the opening. Mark the glass at the supports, once it is centered, using a grease pencil or masking tape. This will help position it properly.
  2.  


WARNING
The windshield fence should be cleaned of most of the old urethane material. Do not grind off or completely remove the old material, or adhesion of the replacement material could be compromised.

  1. Remove the windshield from the opening and place it on a suitable support, clean the inside of the glass. Apply clear glass primer in a 1 in. (25mm) path around the perimeter of the windshield and wipe with a clean cloth.
  2.  
  3. Apply a 5 / 8 in. (15mm) wide path of blackout primer around the top and sides of the windshield. Apply a 1 in. (25mm) path to the bottom of the windshield. Allow 3 minutes drying time.
  4.  
  5. Position one 3 / 16 in. (5mm) windshield bonding compression spacers around the opening for the windshield.
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  7. Apply a 1 / 2 in. high x 3 / 8 wide (13mm high x 10mm wide) bead of urethane around the perimeter of the windshield.
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  9. With the aid of a helper, install the windshield glass in position, aligning the reference marks made earlier. Push the windshield into position until it bottoms on the spacers and the top molding is flush with the roof line.
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  11. Clean excess urethane from the glass using a suitable solvent. Install the moldings.
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  13. Use pieces of masking tape around the windshield to hold the molding until the urethane cures.
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  15. Install the cowl cover and the inside mirror.
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  17. When the urethane cures, remove the tape and water test the windshield for leaks.
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