Jeep Wrangler/YJ 1987-1995 Repair Guide

Windshield Glass

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Windshield components

These vehicles employ a bonded windshield system. If the windshield to be replaced has not suffered major damage, either to the glass or frame, and can be removed intact, then a do-it-yourselfer can perform the job. Even so, a special tool, called an electric hot knife must be used. If, however, the glass has been extensively damaged, or the frame and molding damaged so that a loss of adhesion has occurred, then the job should be left to a professional. The following procedure is a do-it-yourselfer procedure, assuming a simple replacement of an intact glass and good seal-to-glass adhesion.

  1. Remove the wiper arms.
  2.  
  3. Remove the sun visors.
  4.  
  5. Remove the molding cap and molding.
  6.  
  7. Cover all adjacent painted surfaces.
  8.  
  9. Using an electric hot knife under the edge of the glass, cut the adhesive material as close to the inside surface of the glass as possible.
  10.  

Make sure that an even, uniform bead of sealer remains on the body for installation purposes. NEVER ALLOW THE HOT KNIFE TO STOP DURING THE CUTTING PROCESS! Allowing the knife to stop will cause permanent damage to the adhesive material.

  1. Clean old sealant from the windshield opening with naphtha or equivalent.
  2.  
  3. Clean the glass with a glass cleaner that DOES NOT contain silicone.
  4.  
  5. Apply a smooth, continuous bead of approved urethane windshield bonding adhesive material around the entire perimeter of the windshield opening flange.
  6.  
  7. Carefully position the glass in the windshield opening. and press down to set the adhesive. Don't press too hard or too much adhesive will be lost.
  8.  
  9. Remove any sheet metal masking that you applied.
  10.  
  11. Install the windshield molding and cap.
  12.  
  13. Install the sun visors.
  14.  
  15. Install the wiper arms.
  16.  

 
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