Installation For Technicians Only Toyota Tundra Extended Cab By Gilbert Gutierrez. Vehicle information

Transcription

1 Toyota Tundra Extended Cab By Gilbert Gutierrez Vehicle information Vehicle type: Four-door extended cab pickup truck NAGS numbers*: Windshield part numbers FW02724, FW02723, FW02722 or FW02721; front door glass FD R-L; rear door glass FD R-L; and back glass FY95054, FY95053, FB23336, FB23335 and FB Helpful tools or supplies: Retention tape or a rubber hose to protect the fenders and hood; a PryBaby for molding and panel removal. Watch for: Be careful not to pull too hard on the rearview mirror harness during removal to avoid ripping the headliner. When removing or reinstalling the A-pillar trim panels, take care to avoid disturbing the curtain air-bag harness. *With permission from National Auto Glass Specifications. Call NAGS at 800/ or visit Editor s note: Please see Toyota Tundra Crew Cab installation on Page 35 for windshield and front door glass photography. A. Windshield Preparation 1. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. Note: Always wear eye and hand protection when working with glass. Make sure you have the right glass and the urethane systems are current. Windshield part numbers are FW02724, FW02723, FW02722 or FW Remove the rearview mirror by loosening the Tork screw using a T-20 Tork screwdriver. Slide the wire-harness trim cover off the headliner. Slide the mirror off the mirror bracket in an upward motion. 3. Disconnect the wire harness from the underside of the hardware using a small flat-tip screwdriver or your fingernails. 4. Remove the windshield-wiper nuts using a wrench or socket. If the nuts are tight, loosen them with a 14-millimeter wrench and then come back with your socket. Move the wiper arm in an up-and-down motion to break it loose from the post, or use a wiper puller. Caution: Wipers can sometimes be hard to remove. To avoid stressing the post, use a wiper puller. The wipers are marked; take note to ensure proper reinstallation. 5. Using a No. 2 Phillips-tip screwdriver, remove the two plastic screw inserts on the fasteners on the outer edge of the cowling corners. There is one on the passenger s side and one on the driver s side. 6. Remove the rubber corner pieces from the corners of the cowling at the base of the windshield. Using an outward motion, pull out the rubber piece, then gently pull the rubber insert from the cowling. 7. With the hood open, push in and pop loose the six plastic tab fasteners using a No. 1 PryBaby tool from the underside. There are three fasteners on the passenger s side and three on the driver s side, with a guide pin at the center. 8. Remove the two-part cowl by sliding it in an upward-outward motion toward the engine compartment, disengaging the eight underside tabs on the front part of the cowling from the base of the windshield. Tape the hood and fender with molding-retention tape to avoid gnarling or scratching the cowling. Note: When re-installing the cowling, use a No. 1 PryBaby tool to assist in the installation of the cowling onto the bottom of the windshield. 9. If using a cold knife or power tool for cutout, remove the A- pillar trim panels, as the windshield fits close to the pinchweld. 10. Remove the door weatherstrip. 11. Remove the screw covers using a No. 2 PryBaby tool. 12. Remove the two 10-millimeter bolts hidden beneath the covers using a 10-millimeter socket-wrench driver. Pull the handle loose. 13. Remove the A-pillar trim panels using a door-panel remover or No. 2 PryBaby tool. Caution: Be careful not to disturb the curtain air-bag harness when removing or reinstalling the A-pillar trim panels. Note: Before beginning windshield removal, verify the new windshield is the correct one and the urethanes and primers are current. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers. Removal 14. Make sure cutting blades are sufficiently sharp. 15. Before cutting out the windshield, remove contaminants from the glass and pinchweld to prevent contact with the urethane. 16. If using a cold knife, use a 3 4-inch blade. Cut three sides; then use a long knife or power tool to cut the bottom of the windshield. Note: There are no gravity stops on this windshield. 17. If trying to save the windshield, use an Equalizer with an 8-inch blade. When using any power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts. 18. After cutting the sides and top, cut the area on the bottom portion using an Equalizer Express. Spray the bottom of the windshield with water at least 4-to-5-inches above the urethane on the glass, so the water flows down into the urethane while you make your final cut across the bottom of the windshield. Caution: Never use your head to push, as this could result in back and neck injuries. 19. Take the windshield out of the opening using a set of Installation AutoGlassmagazine.net 43

2 Installation vacuum cups. Lift the glass and place it on a windshield stand or suitable workstation. Installation 20. After cutting the windshield out, remove contaminants such as dirt, moisture and other debris from the pinchweld. Clean the dashboard. 21. Dry fit the new glass to the opening. Mark your glass using a grease pencil or molding-retention tape. 22. Place your vacuum cups on the windshield in the appropriate location for a one-person set. 23. For driver-side setting of the windshield using a Glass Handler Kit, place the kit s elbow-setting pad on the driver s side of the hood area; then lift the windshield from the stand using the vacuum cups. 24. Reach over, place your elbow on the setting pad and set the windshield onto the old urethane. 25. With the windshield resting in the opening, make sure it is in the right spot. 26. Adjust both sides to the correct setting, marking the passenger s side, then the driver s side. Lift the glass and place it on a windshield stand or suitable workstation. 27. Follow the urethane manufacturer s recommendations for installation. 28. Clean the inside of the windshield using a urethane manufacturer-recommended product; follow recommended steps. Note: Do not touch the windshield after cleaning, prepping or priming it. 29. Wear powder-free Nitrile gloves to keep off chemicals. 30. Apply the glass prep and primer, following the urethane manufacturer s recommendations. 31. Using a pinchweld-preparation tool, remove as much of the original urethane as the urethane manufacturer recommends. Note: Before removing the old urethane, make sure there are no contaminants and do not touch the pinchweld after you have prepped the area. 32. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer. 33. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Note: Before cutting your V-notch with a Top Notch tool, cut the tip off of your nozzle with a nozzle cutter. With the cut nozzle, measure to the top of the roofline, and at 1 16 inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead. 34. Lift the windshield from the windshield stand or workstation using vacuum cups. Reach over, place your elbow on the setting pad and set the windshield on the urethane at the mark you made during dry fit. Lower the driver s side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place. 35. The windshield is now ready to be decked. Press firmly to ensure a good seal. 36. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply pressure to the spot to ensure the glass makes contact with the wet urethane. 37. Re-install the removed parts in reverse order. 38. Allow the urethane to cure according to the urethane manufacturer s recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe driveaway time that your urethane manufacturer recommends could jeopardize the structural integrity of the car and the safety of its passengers. 39. You have completed the removal and replacement of the windshield. B. Front door glass Removal 1. Make sure you have the right glass. Front door glass part numbers are FD R-L. 2. To remove the door panels, pry off the trim cover on the door-handle assembly using an installation stick or a No 2 PryBaby. 3. Remove the No. 1 Phillips screw behind the trim cover. 4. Remove the trim cover from the armrest-pull handle using a small flat-tip screwdriver or a rubber hook tool. 5. Remove the No. 1 Phillips screw beneath the trim cover. 6. Pop loose and remove the door-mirror trim cover using an installation stick or No. 1 PryBaby tool. 7. Remove the push-in plug fasteners from the front side of the trim panel using a rubber hook tool to push the center push-in plug in. Use a No. 3 Pry Baby to get behind the panel and your fingers to remove the fastener. 8. Open the door-panel compartment, slip in an installation stick from the underside of the electrical window-switch assembly and gently push up to disengage the assembly. Disconnect the electrical window-switch assembly harness by pinching the tab and pulling the harness free. 9. Pop loose the trim panel using a door-panel remover or a No. 2 PryBaby tool to disengage the eight plastic fasteners located about 12-to-14 inches from the top of the door panel. 10. In an upward-outward motion, gently pull the door panel and disengage it from the door. 11. Disengage the door-handle assembly by pulling the two cable ball joints from the lock (a white plastic piece) and doorhandle assembly (a green plastic piece) away from the panel. 12. Disconnect the light-assembly harness by pinching the tab and pulling the harness free. 13. Set the door panel in a safe place. 14. Remove the plastic sound-weather barrier. 15. Remove the four 10-millimeter bolts from the speaker and put it aside; this will give you access to the front plastic glass retainer. 16. Lower the glass to align the mounting hardware with the opening. 17. Remove the two 10-millimeter bolts on the plastic glass retainers. There is one on the front of the door and one on the rear, on the regulator arms. 18. Remove the glass by lifting the backside first to disengage it from the weatherstrip channel. 44 AutoGlass March/April 2008

3 C2 C4 C7a C7b Replacement 19. To replace the door glass, slip it back into the door in the same manner you removed it. Make sure it is fully in the weatherstrip channel and not on the backside of the metal carrier. Align the carrier before bolting it to the plastic hardware on the glass. 20. Check the operation of the glass before replacing the panel to ensure proper installation. 21. Re-install the removed parts in reverse order. 22. You have completed the removal and replacement of the front door glass. C3 C6 C8a C8b C. Rear door glass Removal 1. Make sure you have the right glass. Rear door glass part numbers are FD R-L. 2. To remove the door panels, first pry off the trim cover on the door-handle assembly using an installation stick or a No. 2 PryBaby. 3. Remove the No. 1 Phillips screw behind the trim cover. 4. Remove the trim cover from the armrest-pull handle using a small flat-tip screwdriver or a rubber hook tool. 5. Remove the No. 1 Phillips screw beneath the trim cover. 6. Pop loose and remove the upper-door rear-side trim cover using an installation stick or plastic door-panel removal tool. There are three fasteners. 7. To remove the push-in plug fasteners from the rear side of the trim panel, use a rubber hook tool to push the center push-in plug in. Get behind the panel with a No. 3 PryBaby tool, and use your fingers to remove the fastener. 8. Slip in an installation stick from the underside of the electrical window-switch assembly and gently push up to disengage the assembly. Disconnect the electrical windowswitch assembly harness by pinching the tab and pulling the harness free. 9. Pop loose the trim panel using a door-panel remover or a No. 2 PryBaby tool to disengage the nine plastic fasteners located about 12-to-14 inches from the top of the door panel. 10. In an upward-outward motion, gently pull the door panel Installation AutoGlassmagazine.net 45

4 Installation C11a C11b C17c C17d C11c C11d C18a C18b C14 C15 C20a C20b C17a C17b C21a C21b and disengage it from the door. 11. Disengage the door-handle assembly by pulling the two cable ball joints from the lock (a white plastic piece) and door handle assembly (a green plastic piece) away from the panel. 12. Disconnect the light-assembly harness by pinching the tab and pulling the harness free. 13. Disconnect the speaker-assembly harness by pinching the tab and pulling the harness free. 14. Set the door panel in a safe place. 15. Remove the plastic sound-weather barrier. 16. Raise the glass all the way to the up position. 17. Remove the four 10-millimeter bolts from the glasschannel run. There is one at the top, another 8 inches down, a third at the midsection and a fourth at the bottom of the door closest to the opening. 18. Break loose the foam at the top of the glass-channel run. Disengage the glass-channel run and slip it out of the door through the lower opening. 19. Lower the glass. 20. Remove the glass by lifting the backside first to disengage it from the weatherstrip channel. Slip the roller off and slip the glass through the inner-side of the doorframe between the weatherstripping and the cutout notch at the top of the frame. Replacement 21. To replace the door glass, slip it back into the door in 46 AutoGlass March/April 2008

5 C21c D3d D4 Installation D2a D5a D5b D2b D3a D7a D7b D3b the same manner you removed it and slide the glass channel back onto the regulator roller. Make sure it is fully in the weatherstrip channel and not on the backside of the metal. Align the glass before bolting the glass-channel run hardware onto the door. Note: When re-installing the glass-channel run, use glass cleaner as a lubricant to slide the channel back into place. Make sure that the channel is behind the upper weatherstripping. 22. Check the operation of the glass before replacing the panel to ensure proper installation. 23. Re-install the removed parts in reverse order. 24. You have completed the removal and replacement of the rear door glass. D3c D7c D. Back glass Removal 1. Make sure you have the right glass. Back glass part numbers are FY95054, FY95053, FB23336, FB23335 or FB To remove the rear twopart seat, remove the two 10- millimeter bolts on the driver s side. There is one on the back wall and another at the floor base hardware. 3. Remove the four 14-millimeter bolts on the passenger s side. There is one on the back wall closest to the smaller seat section and another at the floor base hardware. Remove the third bolt on the back wall at the quarter panel and the fourth at the floor base hardware. 4. Slip the three seatbelt buckles through their portholes. 5. In an upward, outward, pushing and pulling motion, disengage the two-part back cushion section away from the seats, four hooks away from the mounting bars on the back wall. 6. Set the back seats in a safe place. 7. Using a No. 2 PryBaby tool or panel remover, remove the AutoGlassmagazine.net 47

6 Installation D8 D9 D13b D13c D10a D10b D14a D14b D11a D11b D14c D15a D11c D13a D15b D15c two SRS curtain airbag trim covers, one on the driver s side and another on the passenger s side. Use a 10-millimeter socket wrench to remove the two bolts behind the trim covers. 8. Remove the door weatherstripping. 9. Remove the three, child-seat safety hardware pieces. There are two on the driver s side and one on the passenger s side. Use a 12-millimeter socket wrench to remove the bolts. 10. Remove the two-part quarter trim panels with a No. 3 PryBaby tool or panel remover. Start by removing the five pushin fasteners around the lower trim panel and the four push-in fasteners and 10-millimeter bolt on the upper section. 11. To remove the two coat-hanger hooks, remove the trim cover with a No. 2 PryBaby tool. Pinch the metal clip together and pull the hook portion loose. There is hook on the driver s side and one on the passenger s side. 12. Lower the headliner so you can remove the back glass. If you are not able to remove the back glass, proceed with the following steps. 13. Remove the headliner retainer at the driver door. Remove the trim cover using a No. 2 PryBaby tool. Pinch the metal clip together and pull the headliner retainer portion loose. 14. Remove the passenger-side handle. Remove the trim cover using a No. 2 PryBaby tool. Pinch the metal clip together and pull the handle portion loose. 15. Remove the sun visors. Remove the trim cover on the swivel base using a No. 2 PryBaby tool. There are four Tork AutoGlass March/April 2008

7 D16a D16b D19a D19b Installation D16c D16d D19c D21 D16e D16f 20. When using an Equalizer or any power tool, use water to lubricate the cutting area. Spray the top and sides; then make your cuts. 21. After cutting the bottom and sides, wedge the glass out using Superwedges. Cut the top portion. Note: Tape the glass on the exterior top section so it does not slide off the pinchweld. 22. Take the back glass out of the opening using a set of vacuum cups. Lift the glass and place it on a windshield stand or suitable workstation. D16g D16h screws: one at the visor stop and three on the swivel base. 16. Remove the center console. There are two Tork 20 screws in the garage-door opener compartment and two Tork 20 screws in the sunglasses compartment. There are two more screws underneath the lens. Remove the lens cover using a No. 2 PryBaby tool. Pry the reflector from the light assembly by popping loose the four snap tabs using a No. 2 PryBaby. 17. Make sure cutting blades are sufficiently sharp. 18. Before cutting out the back glass, remove contaminants from the glass and pinchweld to prevent contact with the urethane. 19. If trying to save the back glass, use an Equalizer with a cold-knife blade. Caution: Make sure to cut around the placement clips so they can be used again. Replacement 23. After cutting the back glass out, remove contaminants such as dirt, moisture and other debris from the pinchweld. 24. Dry fit the new glass to the opening. Mark your glass using a grease pencil or molding-retention tape. 25. Place your vacuum cups on the back glass in the appropriate location for a one-person set. 26. Place your back glass onto the old urethane. 27. With the back glass resting in the opening, make sure it is in the right spot. 28. Adjust both sides to the correct setting, marking the passenger s side, then the driver s side. Lift the glass and place it on a windshield stand or suitable workstation. 29. Follow the urethane manufacturer s recommendations for installation. Verify the urethanes and primers are current. 30. Clean the inside of the back glass using a urethane manufacturer-recommended product; follow recommended steps. Note: Do not touch the bonding area of the back glass after cleaning, prepping or priming it. 31. Wear powder-free Nitrile gloves to keep off chemicals. 32. Apply the glass prep and primer, following the urethane manufacturer s recommendations. 33. Using a pinchweld-preparation tool, remove as much of the original urethane as the urethane manufacturer recommends. AutoGlassmagazine.net 49

8 Installation Note: Before removing the old urethane, make sure there are no contaminants and do not touch the pinchweld after prepping the area. 34. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer. 35. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Note: Before cutting your V-notch with a Top Notch tool, cut the tip off of your nozzle with a nozzle cutter. With the cut nozzle, measure to the top of the roofline, and at 1 16 inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead. 36. Using vacuum cups, lift the windshield from the windshield stand or workstation. Reach over, place your elbow on the setting pad and set the windshield on the urethane at the mark you made during dry fit. Lower the driver s side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place. 37. The windshield is now ready to be decked. Press firmly to ensure a good seal. 38. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply pressure to the spot to ensure the glass makes contact with the wet urethane. 39. Re-install the removed parts in reverse order. 40. Allow the urethane to cure according to the urethane manufacturer s recommended cure time before returning the vehicle to the customer. 41. You have completed the removal and replacement of the back glass. The author is senior technical advisor for Equalizer Industries, Round Rock, Texas. Write him at ggutierrez@equalizer.com. A special thanks to Equalizer CEO Ray Asbery for providing the vehicle. Notes: 50 AutoGlass March/April 2008