Jeep Wrangler TJ. Manual — part 560
QUARTER GLASS
REMOVAL
(1) Cover surface areas with protective covering to
avoid paint damage and extra clean-up time.
(2) Using a razor knife, slide the blade between
the quarter glass and the inboard edge of the reveal
molding.
(3) Cut around the interior perimeter of the reveal
molding and sever the cap of the reveal molding.
(4) Using a cold knife, cut the urethane around the
perimeter of the quarter glass.
(5) Remove the quarter glass from the opening
(Fig. 1).
INSTALLATION
(1) Trim the urethane from the quarter glass open-
ing fence. Leave a 3 mm (0.1 in.) level base of ure-
thane on the quarter glass opening fence.
(2) Place replacement quarter glass into quarter
glass opening and position glass in the center of the
opening against fence.
(3) Verify the glass lays evenly against the fence at
the sides, top and bottom of the replacement quarter
glass. Next, make alignment marks on glass and top
with a grease pencil.
(4) Remove replacement quarter glass from open-
ing.
(5) Position the quarter glass inside up on a suit-
able work surface.
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN QUARTER GLASS BEFORE
APPLYING
GLASS
PREP AND
PRIMER.
POOR
ADHESION CAN RESULT.
(6) Clean inside of quarter glass with ammonia
based glass cleaner and lint-free cloth.
(7) Clean the outer edge of the window glass with
naphtha or a similar product.
(8) Apply molding to perimeter of quarter glass.
The butt weld of the molding should be centered at
the bottom edge of the quarter glass.
(9) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of the quarter glass and
wipe with clean/dry lint-free cloth until no streaks
are visible.
(10) Apply Glass Primer 25 mm (1 in.) wide
around perimeter of quarter glass. Allow at least
three minutes drying time.
(11) Apply Pinchweld primer 15 mm (0.75 in.) wide
around the quarter glass fence. Allow at least three
minutes drying time.
(12) Apply a 10 mm (0.4 in.) diameter bead of ure-
thane to the center of the quarter glass fence surface
area.
CAUTION: Be prepared to install the quarter glass
immediately after applying the adhesive. The adhe-
sive begins to cure within 10-15 minutes.
(13) Align the quarter glass with the grease pencil
marks and position quarter glass on fence.
(14) Push the quarter glass inward until the
reveal molding is seated on the hardtop. Use care to
avoid excessive squeeze-out of adhesive.
(15) Open windows and liftgate to prevent pres-
sure build-up while the urethane is curing.
(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
quarter glass in place until urethane cures.
(17) After urethane has cured, remove tape strips
and water test quarter glass to verify repair.
Fig. 1 HARD TOP QUARTER GLASS
1 - HARD TOP
2 - QUARTER GLASS REVEAL MOLDING
3 - QUARTER GLASS
23 - 82
STATIONARY GLASS
TJ
WINDSHIELD
REMOVAL
The windshield is positioned in the reveal molding
and is bonded to the windshield frame with urethane
adhesive. The windshield interior trim molding is
positioned onto the inner windshield frame pinch-
weld.
(1) Cover body surface areas with protective cover-
ing to avoid paint damage and extra clean-up time.
(2) Remove the windshield wiper arms. (Refer to 8
- ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(3) Remove the rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR
VIEW
MIRROR
-
REMOVAL)
(4) Using a razor knife, slide the blade between
the windshield glass and the inboard edge of the
reveal molding.
(5) Cut around the interior perimeter of the reveal
molding and sever the cap of the reveal molding.
(6) Using a cold knife, cut the urethane around the
perimeter of the windshield.
(7) Remove the windshield glass from the frame
(Fig. 2).
INSTALLATION
(1) Trim the urethane from the pinchweld flanges.
Leave a 3 mm (0.1 in.) level base of urethane on the
pinchweld flanges.
(2) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against pinchweld flange.
(3) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinchweld flange
must be formed to the shape of the new glass. Next,
make alignment marks on glass and body with a
grease pencil.
(4) Remove replacement windshield from wind-
shield opening.
(5) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 3).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER
TO
CLEAN
WINDSHIELD
BEFORE
APPLYING
GLASS
PREP AND
PRIMER.
POOR
ADHESION CAN RESULT.
(6) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(7) Apply molding to perimeter of windshield. The
butt weld of the molding should be centered at the
bottom edge of the windshield.
(8) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(9) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(10) Apply Pinchweld primer 15 mm (.75 in.) wide
around the windshield fence. Allow at least three
minutes drying time.
(11) Apply a urethane bead (Fig. 4) on the pinch-
weld flange surface area 6 mm (.25 in.) from the out-
board edge.
CAUTION: Be prepared to install the windshield
glass immediately after applying the adhesive. The
adhesive begins to cure within 10-15 minutes.
(12) Align the windshield with the grease pencil
marks and position windshield on pinchweld flanges.
(13) Push the windshield glass inward until the
reveal molding is seated on the windshield frame.
Use care to avoid excessive squeeze-out of adhesive.
(14) Open windows and liftgate to prevent pres-
sure build-up while the urethane is curing.
(15) Starting in each corner, apply 150 mm (6 in.)
lengths of 50 mm (2 in.) masking tape spaced 250
mm (10 in.) apart to hold windshield in place until
urethane cures.
(16) Install the rear view mirror support bracket.
(Refer to 23 - BODY/INTERIOR/REAR VIEW MIR-
ROR SUPPORT BRACKET - INSTALLATION)
(17) Install the rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR - INSTAL-
LATION)
Fig. 2 WINDSHIELD
1 - WINDSHIELD
2 - INNER TRIM MOLDING
3 - WINDSHIELD FRAME
4 - WINDSHIELD MOLDING
TJ
STATIONARY GLASS
23 - 83
(18) Install the wiper arms. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
ARMS
-
INSTALLATION)
(19) After urethane has cured, remove tape strips
and water test windshield to verify repair.
WINDSHIELD HINGE
REMOVAL
NOTE: If both hinges are to be replaced, the wind-
shield must be tilted to the full forward position.
(Refer to 23 - BODY/STATIONARY GLASS/WIND-
SHIELD - REMOVAL)
(1) Remove door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
(2) Remove the bolts attaching the hinge to the
cowl (Fig. 5).
(3) Remove the bolts attaching the hinge to the
windshield frame.
(4) Separate the hinge from the vehicle.
INSTALLATION
(1) Paint as required.
(2) Clean the contact surface of the hinge and cowl
with isopropyl alcohol or equivalent.
(3) Apply a 4 mm bead of Mopar
t Vinyl Acrylic
Sealant or equivalent around the perimeter of the
hinge contact surface. The bead should be 10 mm
inboard of the edge.
(4) Position the hinge on the vehicle.
(5) Install the bolts attaching the hinge to the
windshield frame.
(6) Install the bolts attaching the hinge to the
cowl.
(7) Ensure that the sealant provides complete cov-
erage. Wipe away excess sealant.
(8) Install door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - INSTALLATION)
Fig. 3 WORK SURFACE SET UP AND MOLDING
INSTALLATION
1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS
Fig. 4 URETHANE BEAD
1 - WINDSHIELD
2 - MOLDING
3 - URETHANE BEAD
Fig. 5 WINDSHIELD HINGE
1 - COWL
2 - WINDSHIELD
3 - WINDSHIELD HINGE
23 - 84
STATIONARY GLASS
TJ
WINDSHIELD (Continued)
WINDSHIELD FRAME
REMOVAL
(1) Unlatch top.
(2) Remove the bolts attaching the sport bar to the
windshield frame.
(3) Remove the windshield wiper arms. (Refer to 8
- ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(4) Remove the torx screw closest to the hinge
pivot point and tilt the windshield forward.
(5) Remove the torx screws attaching the wind-
shield hinge to the windshield frame (Fig. 6).
(6) Separate the windshield frame from the vehi-
cle.
INSTALLATION
NOTE: Inspect windshield to cowl seal for damage
and confirm correct position.
(1) Position the windshield frame on the vehicle.
(2) Install the torx screws attaching the wind-
shield hinge to the windshield frame.
(3) Tilt the windshield rearward.
(4) Install the torx screw closest to the hinge pivot
point and lock the windshield in the upright position.
(5) Install the windshield wiper arms. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
INSTALLATION)
(6) Install the bolts attaching the sport bar to the
windshield frame.
(7) Latch top.
Fig. 6 WINDSHIELD FRAME
1 - WINDSHIELD HOLD DOWN LOOP
2 - WINDSHIELD HINGE
TJ
STATIONARY GLASS
23 - 85
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