How to Replace or Repair Auto Glass Windows

Broken glass is an eyesore and safety concern.

Vehicle owners often overlook damaged door glass when the damage appears minimal. However, the importance of repairing or replacing chipped or broken windows should not be put off or ignored. Damaged glass can hamper vision, leading to misjudgments and accidents. Spider cracks or exposed slivers can cause injury if touched with bare hands. In addition, the condition of the auto glass on your vehicle poses instant value considerations when you sell or trade in the vehicle. Although time consuming and challenging, the average vehicle owner can repair or replace his own windows if he follows precise steps and uses the proper tools.

Things You'll Need

• Door handle remover (horseshoe-shaped)
• Screwdrivers (Phillips and slot-head)
• Ground tarp
• Masking tape
• New glass
• Epoxy glue
• Shop vacuum
• Socket set (1/4-inch)
• Glass cleaner
• Towels
• Pliers
• Assistant
• Gloves
• Window repair kit

Instructions

Window Replacement

1. 

   Clean, undamaged windows provide clear visibility.

   Set the vehicle in park and set the emergency brake. If you have electric windows, run the damaged window down to the bottom position.

   Disconnect the negative battery terminal.

   Spread a tarp on the floor underneath the door frame

2. 

   Safety gloves protect hands when handling broken glass.

   Remove all of the broken glass from the frame with pliers and a slot screwdriver. Wear gloves while removing the glass. Be careful not to damage the felt or rubber window guide grooves.

3. Sit beneath the open door and use a Phillips screwdriver to remove the armrest and any door handle casings from the inside of the door panel. Use a horseshoe-shaped door handle remover to remove the spline-type crank handles.

   Pry loose or unscrew the switch panel and disconnect the electrical connector on the back.

4. 

   Use the proper sockets to remove door panels.

   Using the proper socket, remove the door panel mounting bolts through the door handle and switch panel access holes. Remove the screw-type push-lock knobs (if equipped).

5. Unsnap the door panel by wedging the panel-door removal tool up under the seam to surround the retaining clips. Pry at the bottom and work around both sides until you reach the top. Pull the panel free and set it aside.

   Pull the plastic weather guard from the panel.

   Vacuum all the glass from the bottom of the door panel.

6. Locate the window guide rails on both sides of the window. Use a socket to loosen the frames and gently pry outward (this will loosen the glass pane). Pull any plastic clips free from the window edges and mark their locations exactly.

7. Lift the damaged glass pane straight up and out of its top slot (if you have left the damaged window intact). If you removed the window entirely, guide the new window down through the slot, carefully aligning it with the support rails.

   Reinstall the plastic clips.

8. Seat the new window in the bottom support frame and carefully push the side rails back into to the window edges.

   Holding the rails in place, screw them back into their mount holes. Do one side at a time, making sure the window sits level.

   Reconnect the battery and run the window up, making sure it tracks smoothly. Adjust if needed. If your window has a hand crank, use it in the same fashion. Disconnect the battery.

9. Reassemble the door parts in the reverse order that you disassembled them (glue the weather guard back on, reconnect the switch panel connector, snap the door panel on its fasteners, secure the door panel bolts, reinstall the switch panel and arm rest, and snap the door and window cranks back onto their shafts (if the window is equipped with manual cranks).

Repairing Window Chips

1. Open the window repair kit and follow the instructions to the letter. Place the adhesive patch over the crack or chip and affix the syringe pedestal on it.

2. Mix the chemicals according to directions and load the syringe. Depress the plunger to the prescribed line. Pull the plunger up in the vacuum position and let sit for five minutes.

3. Repeat the vacuum and pressure steps according to instructions, waiting the recommended time intervals between steps. Leave the syringe and mount attached and let set for four hours.

   Remove the syringe, mounting and adhesive patch. Wipe clean.

Tips & Warnings

• An assistant can help you align your new window.

• Replace the bolts and screw in the precise order they were removed.

• Always wear gloves when working with broken glass.

References

• 2CarPros: How Do I Check And Replace My Electric Power Window Motor?
• Car Window Repair: Window Glass Replacement
• AutoMedia: Window Chip Repair

Resources

• "Auto Repair Shams and Scams"; Chris Stevenosn: 1990