Windshield

Complete removal and installation of the front windshield glass, including trim removal, adhesive cutting, glass removal, and installation with new urethane adhesive.

Warnings

Tools required

Parts

• Windshield glass × 1 — Use OEM specification with antenna and tint to match original
• Urethane windshield adhesive × 1 — Mopar or equivalent automotive grade urethane
• Urethane primer (glass and pinchweld) × 1 — Part of windshield adhesive kit
• Windshield molding clips × 1 — Replace any broken during removal
• Upper windshield trim molding × 1 — Replace if damaged during removal

Preparation

1. Park vehicle on level surface and engage parking brake
2. Cover hood, fenders, and dashboard with protective blankets to prevent damage from tools or glass
3. If equipped, disconnect windshield antenna connector from base of A-pillar (driver side)
4. Remove interior rearview mirror by loosening mounting screw or button (depending on type) - mark position for reinstallation
5. Disconnect any windshield washer nozzle hoses if routed through cowl panel
6. Have a second person available to assist with glass handling

Procedure

1. 1

   Remove upper windshield trim molding
   Locate the upper windshield trim/finish molding on the windshield frame. Verify the exact retention method against a Viper service manual, as the 1992 Viper roadster uses a structural windshield frame rather than a roof-header clip-in molding. Use a plastic trim tool to carefully release any retainers, working slowly along the length. Once released, lift the molding away and inspect retainers for damage.ing aside in a safe location. Note: Use OEM specification glass with tint to match original; do not assume an in-glass antenna, as the 1992 Viper roadster was not equipped with a factory radio/antenna as standard.
2. 2

   Remove side windshield trim moldings
   Remove the side trim moldings (A-pillar moldings) on both driver and passenger sides. Confirm fastener type against a Viper service manual before proceeding, as fastener style is not verified for this platform. Remove the fasteners and carefully pry the moldings away from the A-pillar, working from top to bottom. Disconnect any clips or retainers. Set moldings aside with fasteners taped to them for reassembly.
3. 3

   Remove lower windshield cowl cover
   Remove the cowl cover panel at the base of the windshield if equipped. Locate and remove the fasteners securing the cowl cover, confirming fastener type against a Viper service manual. Lift the cowl cover away from the vehicle, disconnecting any washer nozzle hoses if still attached. This exposes the lower windshield edge and provides access for adhesive cutting.
4. 4

   Prepare for windshield removal
   From inside the vehicle, use painter's tape to mark the windshield position on the dashboard if you want to reference original placement. Apply tape along the bottom edge of the glass where it meets the dash. From outside, have your assistant position suction cups on the windshield glass in preparation for removal - one on each side of the glass, positioned to provide balanced lifting points.
5. 5

   Cut urethane adhesive bond
   Using a cold knife or windshield removal tool, carefully insert the blade between the windshield glass and the body pinchweld. Start at the lower corner and work the blade completely around the perimeter of the windshield, cutting through the urethane adhesive. Maintain a shallow angle to avoid scratching the pinchweld or cutting too deeply into the adhesive bed. An alternative is to use a windshield wire pull-through method: insert wire at a corner, feed it through, and have two people pull the wire around the perimeter using a sawing motion. Leave approximately 1-2mm of adhesive on the pinchweld as a base layer.
6. 6

   Remove windshield glass
   With the urethane bond completely cut, have your assistant maintain grip on the suction cups. From inside the vehicle, carefully push outward on the windshield glass while your assistant pulls from outside, using the suction cups for control. Work together to lift the windshield up and out of the opening. Carry the glass to a safe, padded location away from the work area. If the windshield is being reused, inspect it carefully for any chips or cracks.
7. 7

   Clean pinchweld surface
   Using a razor blade scraper, carefully remove old urethane from the body pinchweld, leaving a smooth base layer of approximately 1-2mm thickness. Remove any loose or damaged urethane but do not scrape down to bare metal unless the adhesive is completely compromised. Remove all debris, dust, and loose urethane particles using a shop vacuum. Inspect the pinchweld for rust, damage, or irregularities. If bare metal is exposed, it must be primed before new adhesive application.
8. 8

   Prime pinchweld and prepare new windshield
   Wipe the pinchweld surface with isopropyl alcohol on a clean, lint-free cloth and allow to dry completely. Apply urethane primer to the pinchweld surface according to the adhesive manufacturer's instructions - typically a thin, even coat along the entire perimeter. Allow primer to flash (typically 5-10 minutes, but follow product instructions). For the new windshield, clean the ceramic frit band (black border) with isopropyl alcohol. Apply glass primer to the frit band per manufacturer instructions and allow to flash.
9. 9

   Apply urethane adhesive to windshield
   Load urethane adhesive into the application gun. Starting at the bottom center of the new windshield, apply a continuous bead of urethane around the entire perimeter on the glass frit band. The bead should be approximately 10-12mm wide and 10-12mm high, forming a triangular or V-shaped profile. Maintain consistent bead size and avoid gaps or thin spots. Do not apply so much that excessive squeeze-out will occur, but ensure sufficient adhesive for proper bonding and sealing.
10. 10

    Install windshield glass
    With your assistant, position the suction cups on the outside of the new windshield glass. Carefully lift the windshield and align it with the body opening, using your tape reference marks if present. Lower the windshield into position, ensuring even gaps all around. Once aligned, press firmly around the entire perimeter to compress the urethane and create a proper bond. Apply steady, even pressure but avoid excessive force that could crack the glass. Check that the windshield sits flush with the body and that gaps are consistent.
11. 11

    Secure and cure windshield
    Install retention tape or use support props to hold the windshield in position during initial cure (typically 1-2 hours). Do not slam doors or disturb the vehicle during this period. Wipe away any excess urethane squeeze-out from the edges using a clean cloth dampened with mineral spirits, working carefully to avoid disturbing the seal. Check the seal around the entire perimeter for gaps or voids. Allow the urethane to cure per manufacturer instructions before reinstalling trim or moving the vehicle - typically 24 hours for full cure.
12. 12

    Reinstall cowl cover and trim
    After the urethane has reached safe-drive-away time (typically 1-2 hours, check adhesive specifications), reinstall the lower cowl cover panel. Reconnect any washer nozzle hoses and secure the cowl cover with its original fasteners. Reinstall the side A-pillar trim moldings, securing fasteners and engaging all clips. Finally, install the upper windshield trim molding, ensuring all clips engage properly along its length.
13. 13

    Reinstall accessories and final checks
    Reconnect the windshield antenna connector if equipped. Reinstall the interior rearview mirror at the marked position or per manufacturer specifications. Remove all protective coverings from the vehicle interior and exterior. Clean any adhesive residue from glass using appropriate cleaner. Inspect the installation for any gaps, misalignment, or adhesive voids.

Reassembly

1. Ensure all trim moldings are fully seated and all clips are engaged before considering the job complete
2. Torque all fasteners to specification - use appropriate torque values for trim screws and panel fasteners
3. Do not wash the vehicle or subject it to water spray for 24 hours after installation to allow full adhesive cure
4. Keep windows slightly open during cure period to equalize pressure if possible

Verification

• Visually inspect the windshield installation from inside and outside - gaps should be even all around with no visible voids in the adhesive
• Check that all trim pieces are properly installed and secure with no loose clips or missing fasteners
• After 24-hour cure period, perform a water leak test using a gentle spray from a hose, working around the perimeter while an assistant checks for leaks from inside
• Verify rearview mirror is secure and windshield antenna (if equipped) is functioning properly
• Test windshield wipers for proper clearance and operation - they should not contact trim pieces

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