REMOVAL & INSTALLATION
See Figure 1
- Lower the tailgate.
- Remove the lower trim mouldings from the roof panels.
- Scribe the locations of each trim moulding bracket and number each bracket as it is removed.
- Remove all the roof attaching bolts and trim bolts.
- With at least one other person, carefully lift the roof off of the body. Be careful to avoid tearing the weather-stripping. Be careful to avoid over-flexing the roof. The roof weighs about 120 lbs.
- Installation is the reverse of removal. Torque the roof retaining bolts to 72-84 inch lbs. (8-9 Nm).
See Figure 2
You'll need an assistant for this job.
- Have your assistant stand outside and support the glass.
- Working from the inside truck, start at one upper corner and work the weather-stripping across the top of the glass, pulling the weather-stripping down and pushing outward on the glass until your assistant can grab the glass and lift it out.
- Remove the mouldings.
- Remove the weather-stripping from the glass.
- Clean the weather-stripping, glass and glass opening with solvent to remove all old sealer.
- Apply liquid butyl sealer C9AZ-19554-B, or equivalent, in the glass channel of the weather-stripping and install the weather-stripping on the glass.
- Install the mouldings.
- Apply a bead of sealer to the opening flange and in the inner flange crevice of the weather-stripping lip.
- Place a length of strong cord, such as butcher's twine, in the flange crevice of the weather-stripping. The cord should go all the way around the weather-stripping with the ends, about 18 in. (457mm) long each, hanging down together at the bottom center of the window.
- Apply soapy water to the weather-stripping lip.
- Have your assistant position the window assembly in the channel from the outside, applying firm inward pressure.
- From inside, you guide the lip of the weather-stripping into place using the cord, working each end alternately, until the window is locked in place.
- Remove the cord, clean the glass and weather-stripping of excess sealer and leak test the window.