Rear Window

This procedure covers removal and installation of the rear window glass assembly on a 2009 Aston Martin DB9, including trim removal, adhesive cutting, and proper glass installation with urethane adhesive.

Warnings

Tools required

Parts

• Rear window glass assembly × 1 — Use OEM specification - includes glass with antenna/defroster elements
• Urethane automotive glass adhesive × 1 — High-modulus OEM-approved urethane
• Rear window trim finisher strip × 1 — Reuse if undamaged, or use OEM replacement
• Interior C-pillar trim clips × 1 — Replace any broken during removal

Preparation

1. Park vehicle on level surface in a clean, temperature-controlled environment (ideally 60-80°F for adhesive curing).
2. Disconnect negative battery terminal and wait 15 minutes for airbag system capacitors to discharge.
3. Cover rear parcel shelf, rear seats, and any exposed interior surfaces with protective material.
4. Ensure replacement glass is clean and at room temperature before beginning installation.
5. Have assistant available for glass handling or confirm suction cup lifters are functioning properly.

Procedure

1. 1

   Remove C-pillar interior trim panels
   Working from inside the vehicle, identify the correct interior trim panels surrounding the rear screen per the DB9-specific interior trim layout (the DB9 coupe is a glassback/hatch design, not a sedan with conventional C-pillar panels). Carefully release and remove the applicable trim using plastic trim tools, verifying fastener type before prying. These panels are secured by plastic push clips. Start at the bottom edge and work upward, releasing each clip carefully. Disconnect any courtesy light connectors if equipped. Remove trim panels completely and set aside in protected area. Note: Torx driver set (sizes to be confirmed against 2009 DB9 OEM specifications — do not assume T20/T25/T30) Note: carefully remove the C-pillar trim panels on both sides per Aston Martin OEM procedure. Verify fastener type (clips, concealed screws, and/or adhesive) and leather/Alcantara trim retention method before prying, as these panels are not simple push-clip construction.
2. 2

   Remove rear parcel shelf trim
   Remove the rear parcel shelf trim panel to access the upper edge of the rear window. Locate and remove the Torx fasteners securing the parcel shelf (verify exact count and size against the Aston Martin DB9 workshop manual before proceeding). Gently lift the parcel shelf upward and rearward to disengage any clips along the rear edge. If a center high-mounted stop lamp (CHMSL) connector is present in the work area, disconnect it before removing trim (the DB9 CHMSL is typically mounted near the rear screen/spoiler area rather than on an internal parcel shelf — verify location per OEM documentation). Remove parcel shelf and store safely. Note: Locate and remove the fasteners securing the parcel shelf (count and type unverified for 2009 DB9 — confirm against OEM workshop manual before removal). Note: If equipped at this location, disconnect the center high-mounted stop lamp (CHMSL) electrical connector (verify CHMSL location on 2009 DB9 — may be bootlid-mounted rather than parcel-shelf-mounted). Note: If the center high-mounted stop lamp (CHMSL) is integrated into the parcel shelf, disconnect its electrical connector (verify CHMSL location against OEM documentation, as it may be mounted elsewhere on the DB9). Note: Remove the rear parcel shelf trim panel to access the upper edge of the rear window. Locate and remove the fasteners securing the parcel shelf per Aston Martin OEM documentation (exact count, type, and size to be verified before starting).
3. 3

   Disconnect rear window electrical connections
   Locate the defroster grid electrical connector and antenna connection(s) for the rear window per Aston Martin OEM wiring documentation (verify exact locations and whether an antenna amplifier is fitted before disconnecting). Carefully disconnect both connectors by releasing locking tabs. Note routing of wiring harness for reinstallation. If connectors are adhesive-bonded to glass, carefully separate using plastic tool - do not pull on wires.
4. 4

   Remove exterior trim finisher
   From outside the vehicle, carefully remove the upper rear window trim finisher strip if equipped. This trim typically clips into place or is secured with adhesive. Use plastic trim tools to gently pry upward along the length of the trim. Work slowly to avoid breaking clips. If adhesive-mounted, use a heat gun on low setting to soften adhesive before removal.
5. 5

   Mark glass position and apply protection tape
   Before cutting adhesive, use masking tape to mark the exact position of the glass on the exterior body panel at multiple reference points (top corners and center). This ensures proper alignment during reinstallation. Apply masking tape along the perimeter of the body opening approximately 1 inch from the glass edge to protect paint during adhesive removal.
6. 6

   Cut urethane adhesive bond
   Working from inside the vehicle, insert cold knife, fiber line, or piano wire through the adhesive bond between glass and body per Aston Martin OEM glass removal procedure, taking extra care as the DB9 uses a bonded aluminum body structure. Begin at a lower corner and work around the entire perimeter, cutting through the urethane adhesive layer. Maintain shallow cutting depth (1/4 inch maximum) to avoid scratching glass or damaging body flange. Have assistant apply gentle outward pressure on glass from exterior using suction cups as cutting progresses. Complete the full perimeter cut.
7. 7

   Remove rear window glass
   With adhesive fully cut, attach suction cup lifters to the exterior face of the glass at upper corners. With assistant, gently push glass outward from inside while lifting with suction cups from outside. Lift glass up and out of opening once free. Carry glass to safe storage area. Inspect glass edge for any damage if reusing.
8. 8

   Clean and prepare body opening
   Remove all old urethane adhesive from the body flange using utility knife, leaving a thin smooth base layer approximately 1-2mm thick. Do not cut down to bare metal. Trim the old urethane down to a thin, smooth base layer using a sharp blade only. Do not use a power grinder on the DB9's aluminum/composite body flange, as this risks damaging the bonded body structure and paint. Clean the prepared surface thoroughly with isopropyl alcohol and lint-free cloth. Allow to dry completely. Inspect body flange for any rust, corrosion, or damage and address as needed. Note: Trim old urethane with a utility knife or glass prep blade only; do not use a power grinder on the aluminum body flange, as abrasive removal can damage the protective coating and compromise bond integrity and corrosion protection.
9. 9

   Apply primer to body opening
   Apply urethane adhesive primer to the prepared body flange according to manufacturer instructions. Use foam applicator or brush to apply thin, even coat around entire perimeter. Allow primer to flash off for specified time (typically 5-10 minutes) before adhesive application. Do not touch primed surface.
10. 10

    Prepare new glass assembly
    Clean the bonding surface around the perimeter of the new glass with isopropyl alcohol and lint-free cloth. If glass does not have factory-applied adhesive bead, apply ceramic frit primer or activator to the black ceramic band around glass perimeter according to adhesive manufacturer instructions. Allow to flash per manufacturer specifications. Inspect glass for any defects, and verify defroster grid and antenna connections are accessible and undamaged.
11. 11

    Apply urethane adhesive
    Load urethane adhesive cartridge into application gun. Apply a continuous bead of adhesive around the entire perimeter of the glass (if glass has no factory bead) or around the body opening flange. The bead should be triangular in cross-section, approximately 10-12mm wide at the base and 8-10mm high. Ensure no gaps or thin spots in the adhesive bead. Work quickly and smoothly - adhesive has limited working time once applied.
12. 12

    Install rear window glass
    With assistant, position the glass above the body opening using suction cup lifters. Align glass carefully using the reference marks made during removal. Lower glass into opening, ensuring even gap around entire perimeter. Once positioned, press glass firmly into adhesive bed with steady, even pressure around entire perimeter. Avoid excessive movement after initial contact. Use just enough pressure to compress adhesive to approximately 3-5mm thickness between glass and body.
13. 13

    Secure and verify glass installation
    Apply masking tape across the glass and onto the body panel at multiple locations around the perimeter to hold glass in position during curing. Inspect from inside and outside to verify proper seating and uniform adhesive compression. Check that glass is flush with body lines and reference marks align. Verify no gaps exist that could allow water intrusion. Wipe away any excess adhesive squeeze-out with dry cloth before it skins over.
14. 14

    Reconnect electrical connections
    Carefully reconnect the defroster grid electrical connector and antenna amplifier connector, ensuring positive locking engagement. Route wiring harness as noted during removal. If connectors mount to glass with adhesive, use appropriate adhesive to reattach per OEM procedure. Avoid placing stress on connections while adhesive cures.
15. 15

    Reinstall interior trim components
    Reinstall the rear trim panel(s) accessed earlier, reconnecting the CHMSL connector if applicable and securing with the correct fasteners per OEM documentation (verify fastener type and count for this platform). Ensure trim is properly seated. Reinstall C-pillar trim panels on both sides, pressing firmly to engage all push clips. Reconnect any courtesy light connections. Verify all trim pieces are secure and properly aligned. Reinstall exterior trim finisher strip if equipped, ensuring proper clip engagement or adhesive bonding.

Reassembly

1. Reconnect negative battery terminal after all interior trim is reinstalled.
2. Do not remove support tape for at least 1 hour after installation.
3. Vehicle must remain stationary for minimum 4-6 hours to allow adhesive to achieve safe-drive-away strength.
4. Avoid car washes, high-pressure washing near window edges, or slamming doors for 24-48 hours to allow full adhesive cure.

Verification

• Visually inspect glass from interior and exterior to confirm uniform seating, proper alignment with body lines, and consistent gaps.
• Check that all electrical connections for defroster and antenna are secure and functioning by testing defroster operation and radio reception.
• After adhesive cure time (24-48 hours), perform water leak test using gentle spray around window perimeter while observing interior for any water intrusion.
• Verify all interior trim panels are secure with no rattles or loose clips.
• Confirm masking tape reference marks align properly, indicating glass position matches original installation.

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