Repair Pontiac Mid-size 1974-1983 Repair Guide

Windshield

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The bonded windshield requires special tools and expertise. We recommend that replacement procedures be left to professional installers.

REMOVAL





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Fig. Fig. 1 Use an electric cutting tool to cut the window seal

  1. Place protective coverings over the hood.
  2.  
  3. Remove the windshield wiper arms and windshield trim.
  4.  
  5. If equipped with a radio antenna built into the windshield, disconnect the antenna's lead from the lower end of the windshield and tape the lead onto the outer surface of the windshield to protect it from damage.
  6.  
  7. Using a utility knife and the edge of the windshield as a guide, cut through the adhesive material around the entire perimeter.
  8.  
  9. Using a Hot Knife tool No. J-24709-1 and a cold knife, completely cut through the urethane adhesive.
  10.  
  11. With the help of an assistant, remove the windshield from the vehicle.
  12.  
  13. If reinstalling the windshield, perform the following procedures:
  14.  
    1. Place the windshield onto a protective bench or holding fixture.
    2.  
    3. Using a razor blade or a sharp scraper, remove the excessive adhesive from the perimeter of the windshield.
    4.  
    5. Using denatured alcohol or lacquer thinner with a cloth, remove all traces of the adhesive from the perimeter of the windshield.
    6.  


INSTALLATION





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Fig. Fig. 2 Glass spacer installation locations



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Fig. Fig. 3 Applying adhesive to a windshield whose seal is not intact



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Fig. Fig. 4 Preparing an embedded antenna windshield for installation-seal not intact



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Fig. Fig. 5 Installation of the windshield requires two people

Seal Intact

This method is used when no other adhesive materials are used in the installation procedures. When using a new windshield for installation, do not use kerosene or gasoline as a solvent, for a film is left which will prevent adhesion of the sealing material. When using a volatile cleaner, avoid contacting the plastic laminate material (around the edge of the glass) for discoloration and/or deterioration may occur.

  1. To prepare the windshield frame for glass installation, perform the following procedures:
  2.  
    1. Using a sharp scraper or a chisel, clean the excess sealing material from the windshield frame.
    2.  


It is not necessary to remove all traces of the original material; there should be no mounds or loose pieces remaining. If, while removing the old material, the metal surface has been exposed, cover the area with black primer.

  1. Inspect the reveal molding retaining clip(s); if the upper end of the clip(s) are bent (more than 1 / 16 in.) away from the body metal, replace the clip(s).
  2.  

When using weatherstrip adhesive, apply enough material to obtain a water tight seal beneath the spacer; DO NOT allow the material to squeeze out excessively.

  1. Cement the flat rubber spacers to the window opening at the pinchweld flanges; locate the spacers so that they are equally spaced around the perimeter of the windshield.
  2.  
  3. Reinstall the metal supports at the lower edge of the windshield glass.
  4.  

  1. Using an assistant, lift the glass into the window opening; the windshield can be positioned without the use of suction cups. Check the position of the glass, it should not overlap the pinchweld flange (around the entire perimeter) by more than 3 / 16 in. The overlap across the top of the windshield can be corrected by readjusting the lower metal support spacers.
  2.  
  3. Check the relationship of the glass to the contour of the body. The gap between the glass and the pinchweld frame should be between 1 / 8 - 1 / 4 in. If there is difficulty in maintaining this distance, perform one of the following correction methods:
  4.  
    1. Reposition the flat spacers.
    2.  
    3. Apply excessive amounts of adhesive caulking material to the wide gaps.
    4.  
    5. Try another windshield.
    6.  
    7. Rework the pinchweld flange.
    8.  

  5. After the final adjustments have been made, apply pieces of masking tape over the edges of the glass and the body, then slit the tape between the glass and the body. Remove the glass from the opening.
  6.  

The tape will be used for alignment of the glass upon installation and will aid in the clean up operation.

  1. If desired, apply masking to the inboard edge of the windshield; the tape should be placed 1 / 4 in. (from the outer edge) around the top and sides (not the bottom) of the glass.
  2.  
  3. Using alcohol and a clean cloth, clean the inner perimeter of the glass and allow it to air dry.
  4.  
  5. Using the Urethane Adhesive Kit No. 9636067 (two primers are provided), apply primer using the following procedures:
  6.  
    1. Apply the clear primer around the entire perimeter of the glass. Allow the primer to dry for 5 minutes.
    2.  
    3. If refinishing or painting operations are needed for any portions of the glass opening apply the black primer to these portions. Allow the primer to dry for 5 minutes.
    4.  

  7. Using a caulking gun and an adhesive cartridge, apply a smooth continuous bead 3 / 8 in. wide around the entire perimeter of the glass.
  8.  
  9. Reposition the glass to the window opening using the tape as the installation guide. Apply light hand pressure to the glass to ensure a bond to the body opening. Using a small brush or a flat bladed tool, paddle the bonding material around the edge of the glass to ensure a water tight seal.
  10.  
  11. Using a soft, warm water spray, allow the water to spill over the edges of the glass to detect water leaks. If a water leak is encountered, paddle additional material around the leak.
  12.  
  13. Cement rubber spacers between the right and left sides of the windshield and the frame to keep the glass centered during the installation procedures.
  14.  

After the windshield installation, the vehicle must remain at room temperature for 6 hours.

  1. Install the windshield molding strips. Remove the masking tape from the inner perimeter of the windshield; pull the tape toward the center.
  2.  
  3. Complete the installation by replacing all of the removed parts.
  4.  

Seal Not Intact

This method is used in conjunction with unknown adhesive materials such as butyl strips. When using a new windshield for installation, do not use kerosene or gasoline as a solvent, for a film is left which will prevent adhesion of the sealing material. When using a volatile cleaner, avoid contacting the plastic laminate material (around the edge of the glass) for discoloration and/or deterioration may occur.

  1. To prepare the windshield frame for glass installation, perform the following procedures:
  2.  
    1. Using a sharp scraper or a chisel, clean the excess sealing material from the windshield frame.
    2.  


If using Butyl tape or unknown material to install the windshield, it is necessary to remove all traces of the original material. If using a Urethane sealing material, it is not necessary to remove all traces of the original material; there should be no mounds or loose pieces remaining. If while removing the old material, the metal surface has been exposed, cover the area with black primer.

  1. Inspect the reveal molding retaining clip(s); if the upper end of the clip(s) is bent (more than 1 / 16 in.) away from the body metal, replace the clip(s).
  2.  

If using weatherstrip adhesive, apply enough material to obtain a water tight seal beneath the spacer; DO NOT allow the material to squeeze out excessively. Weatherstrip material is not compatible with other replacement adhesives; leaks may develop where the two dissimilar materials are joined.

  1. Cement the flat rubber spacers to the window opening at the pinchweld flanges; locate the spacers so that they are equally spaced around the perimeter of the windshield.
  2.  
  3. Reinstall the metal supports at the lower edge of the windshield glass.
  4.  

  1. Using an assistant, lift the glass into the window opening; the windshield can be positioned without the use of suction cups. Check the position of the glass, it should not overlap the pinchweld flange (around the entire perimeter) by more than 3 / 16 in. The overlap across the top of the windshield can be corrected by readjusting the lower metal support spacers.
  2.  
  3. Check the relationship of the glass to the contour of the body. The gap between the glass and the pinchweld frame should be between 1 / 8 - 1 / 4 in. If there is difficulty in maintaining this distance, perform one of the following correction methods:
  4.  
    1. Reposition the flat spacers.
    2.  
    3. Apply excessive amounts of adhesive caulking material to the wide gaps.
    4.  
    5. Try another windshield.
    6.  
    7. Rework the pinchweld flange.
    8.  

  5. After the final adjustments have been made, apply pieces of masking tape over the edges of the glass and the body, then slit the tape between the glass and the body. Remove the glass from the opening.
  6.  

The tape will be used for alignment of the glass upon installation and will aid in the clean up operation.

  1. If desired, apply masking to the inboard edge of the windshield; the tape should be placed 1 / 4 in. (from the outer edge) around the top and sides (not the bottom) of the glass.
  2.  
  3. If equipped with an embedded antenna, apply an 8 in. butyl filler strip to the bottom inner center surface of the windshield. If not equipped with an embedded windshield antenna the butyl strip is not necessary.
  4.  
  5. Using alcohol and a clean cloth, clean the inner perimeter of the glass and allow it to air dry.
  6.  
  7. Using the Urethane Adhesive Kit No. 9636067 (two primers are provided), apply primer using the following procedures:
  8.  
    1. If equipped with an embedded windshield antenna, apply the clear primer around the entire perimeter (except at the location of the filler strip); If not equipped with an embedded windshield antenna, apply the clear primer around the entire perimeter of the glass. Allow the primer to dry for 5 minutes.
    2.  
    3. If refinishing or painting operations are needed for any portions of the glass opening apply the black primer to these portions. Allow the primer to dry for 5 minutes.
    4.  

  9. Using a caulking gun and an adhesive cartridge, apply a smooth continuous bead 3 / 8 in. wide around the entire perimeter of the glass.
  10.  
  11. Reposition the glass to the window opening using the tape as the installation guide. Apply light hand pressure to the glass to ensure a bond to the body opening. Using a small brush or a flat bladed tool, paddle the bonding material around the edge of the glass to ensure a water tight seal.
  12.  

If equipped with an embedded antenna, paddle additional material at the edges of the butyl strip; avoid the area near the antenna pigtail.

  1. Using a soft, warm water spray, allow the water to spill over the edges of the glass to detect water leaks. If a water leak is encountered, paddle additional material around the leak.
  2.  
  3. Cement rubber spacers between the right and left sides of the windshield and the frame, to keep the glass centered during the installation procedures.
  4.  
  5. Install the windshield molding strips. Remove the masking tape from the inner perimeter of the windshield; pull the tape toward the center.
  6.  
  7. Complete the installation by replacing all of the removed parts.
  8.  

After the windshield installation, the vehicle must remain at room temperature for 6 hours.

 
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