A little tricky, but I'd never done one before. I bought the windshield
and a one piece Cal look rubber kit from So Cal. The shipping on the
windshield was more than the windshild. This is an item you should try
to buy locally, or wait for a bug show in your area.
Tools: sharp knife, soapy water, 14 or 16 gauge insulated wire,
paper towels and rags, friends
Note: I got a good note from Randy who writes that silicon spray is
a bad thing to use when installing a windshield. Silicon never dries
out, and as a result it is possible that in a crash the windshield could
pop out (that's a bad thing). This sounds possible to me, and Randy
is a professional autoglass installer. So, use soapy water to lube the
gasket. I've used soapy water on other rubber installations (especially
bicycle handgrips) and it works great.
- Cut old rubber on the inside to remove inside lip. Gently loosen
rubber from metal body and lift glass and rubber out
- Install new gasket on window. This is tedious.
- Clean the mating surface of the car so the gasket will not leak.
- Make the gasket and metal of the car slippery with soapy water
(don't use silicon).
- Run a strong insulated wire in the rubber where it will go over
the metal of the car
- Lay the windshield in the hole.
- Starting at the top, pull the inner lip of the gasket over the flange
on the car with the wire.
- If things aren't working, ease the windshield out, and repeat steps
5 through 7.
Starting off, you cut the old rubber on the inside. It is impossible
to remove the old rubber intact without breaking the glass. If you cut
the lip off the inside of the rubber, then you can very, very, gently
pry all the way around the rubber until it comes loose from the body.
It will be stuck. Of course, friends to help you ease the glass out
really help. It takes at least two people on the windshield for installation.
I used silicon to make the rubber gasket slippery, but that was a mistake.
Soapy water works just as well, but you don't have to worry about the
windshield poping out later (this is a problem with silicon). Remember,
when removing or installing the windshield, if you bend the windshield
it WILL crack.
I haven't installed rear glass. I removed a rear side window, and put
in a hinged pop out window that I bought used at a VW car show. It is
probably the same process as with the windshield. I did make a concerted
effort on the rear side window to remove it without cutting the gasket.
This is really a two or three person job. It was a real pain to just
get the gasket onto the windshield. It's one of those operations that
takes 30 minutes with your finger tips.
I used some 14 gauge insulated multistrand wire to install the windshield
in the car. You run the wire (or cord or whatever - something that won't
snap if you pull real hard on it) in the gasket gap that fits inside
the car. Clean the body work of the car very carefully. I used rubbing
alcohol, and dried it very well. Lightly lube the car with soapy water.
You and a helper put the windshield in place. You crawl up on the hood,
and press from the outside, while your helper pulls the inner lip into
the car with that wire. You can see the outer gasket kind of suck into
the windshield seat. If the gasket doesn't suck in, and if the lip isn't
well over the inner flange, you either need to adjust the windshield,
or quit and start over. I had to both push in (towards the rear of the
car) and lift the windshield. We started at the top, and the bottom
had the tendency to push out. At one point I was using both knees and
both hands to firmly yet gently hold the $#*&%* thing in place.
It's kind of nerve wracking. Once things are going well it takes only
a minute or two to pull the wire in and seat the whole thing. Viola!
Mine doesn't leak, and I've had no problems.
The inside lip on the rubber gasket was smaller than stock. It didn't
cover that metal clip stuff that holds in the headliner. When So Cal
sold me that Cal look rubber they didn't mention this. I don't know
if all the Cal look rubber doesn't cover the inner lip, or just what
So Cal sells. I'm taking out my headliner, and not replacing it with
the stock item, so I didn't care. This would have been a real show stopper
for some people. If you want those headliner clips covered, ask when
you buy your gaskets.
Kids in the car after the windshield has been removed. The red area
is where the old gasket (my car's original color was red). Clean this
area very carefully. I used water, then rubbing alcohol.
Click to for a larger view. The
metal tab strip is trim retainer. The gasket from SoCal didn't completely
cover this trim retainer on the inside. It was very noticable where
the trim retainer holds the headliner in at the top of the windshield.