September/October  2003

The CuttingEDGE
    new car installations

2004 Chrysler Pacifica

2004 Chrysler Pacifica 

by Phil Ochs

1. GETTING STARTED:
Cowl screws top
Always remember to protect the surfaces of the vehicle that could be damaged. Remove the rear view mirror by loosing the screw and sliding it off of the bracket. Next, remove the wipers by taking off the nut caps and removing the 15-mm nuts. The cowl will have a screw in both outer corners; the remainder of the cowl has push clips—gently pry these upward to release. Then remove the outer exterior trim A-pillar mouldings by gently prying upward. They are held with wedge-style clips. Now remove the top moulding by pulling away from the glass gently.

15mm nuts with caps 2. REMOVING THE ORIGINAL WINDSHIELD: 
We recommend using the full-cut out method. With a cold knife or power cut out tool cut the glass free. Be careful along the sides and top, the sides are recessed and the top has an inverted moulding so the vertical area of the pinchweld will be exposed once the job is completed. Then remove the original urethane leaving a thin skin of well-bonded urethane. Test the bond of the original adhesive by pulling on it as you are removing. Avoid unnecessary damage to the pinchweld’s painted surface.
 
3. PREPARING FOR THE NEW WINDSHIELD:
Interior view
Prime the pinchweld according to your adhesive manufacturer’s specifications. Concentrate only on any areas of the paint that may have been scratched or damaged during the removal process. The freshly cut urethane bed provides the best bonding surface. The auto manufacturer used a primerless-to-paint (P2P) adhesive system. You may need to widen the bonding surface by applying pinchweld primer along the original adhesive bead. Allow proper time for the primers to cure. You will need to apply the top moulding, then clean and prime the windshield according to adhesive manufacturer’s recommendations being sure to duplicate the original bond line. 

The moulding for the top is an inverted-style moulding and will need to be replaced. The OE# for the moulding is 4719858AB.

4. PLACEMENT OF THE NEW WINDSHIELD:
Dry-set the windshield into the opening, being sure to adjust for proper alignment. Remove the windshield and set it onto a cradle with the inboard lite in the upright position. Use a properly cut V-notch tip to duplicate the original bead size. Apply the adhesive to the glass, duplicating the original bond line. Set the windshield into the opening using your dry-set marks for proper alignment, being careful not to slide the windshield once it makes contact with the pinchweld. 

5. FINISHING TOUCHES:
Replace the exterior reveal mouldings, and then replace the cowl by snapping it into place and tightening the screws in each corner. Reinstall the wipers arms and test the wipers for proper alignment. Check the defroster, clean and prep the remainder of the vehicle, and return to the customer.


Phil Ochs is a technical trainer for the Performance Achievement Group in Madison, Wis.

AGRR

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