Rear Window

Complete rear window removal and installation procedure for the 2005 Dodge Viper, including removal of interior trim panels, weather stripping, and fixed glass separation from adhesive.

Warnings

Tools required

Parts

• Rear window glass × 1 — Use OEM specification
• Urethane windshield adhesive kit × 1 — Mopar or equivalent automotive glass adhesive
• Glass primer × 1 — Compatible with urethane adhesive system
• Rear window weather stripping (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow vehicle to cool completely if recently driven
3. Cover rear deck area and adjacent painted surfaces with protective blankets or towels to prevent damage during glass removal
4. Work in a dry, moderate temperature environment (60-80°F ideal for adhesive curing)
5. Have a second person available to assist with glass handling

Procedure

1. 1

   Remove interior rear trim panel
   From inside the vehicle, locate and remove the rear interior trim panel that covers the rear window lower edge. Check for the trim fasteners along the bottom and sides of the panel and verify the correct driver type/size against the service manual before removal. Gently pull the panel away from the body using trim removal tools, releasing any remaining retention clips. Disconnect any speaker connectors or harness connections if present on this vehicle configuration.
2. 2

   Remove rear package shelf (if equipped)
   If your Viper is equipped with a rear package shelf or speaker grille below the rear window, remove the fasteners securing it. These are typically Torx screws accessible from the interior. Lift the shelf away carefully to expose the lower window edge and body structure.
3. 3

   Mark glass position
   Using a wax pencil or masking tape, mark the position of the rear window glass on the exterior body at multiple reference points (top corners and center). This ensures proper alignment during reinstallation. Mark the glass itself with orientation indicators if symmetry is not obvious.
4. 4

   Remove exterior weather stripping
   Carefully peel away any exterior weather stripping or trim molding from around the perimeter of the rear window. The Viper may use a molded rubber seal that is pressed into a channel or bonded to the glass. Inspect the condition of this seal - if cracked or damaged, plan to replace during reinstallation.
5. 5

   Score adhesive perimeter from interior
   From inside the vehicle, use a utility knife to carefully score the urethane adhesive bond between the glass and body pinch weld. Cut through the adhesive approximately 1/8 inch from the glass edge, making a continuous cut around the entire perimeter. Do not cut deeply enough to damage the body paint or structure.
6. 6

   Cut adhesive with cold knife or piano wire
   Using a cold knife windshield removal tool or piano wire technique, cut through the urethane adhesive bond. If using wire, insert it through the adhesive from the exterior at one corner, then have an assistant work from inside while you work from outside in a sawing motion. Work slowly and steadily around the entire perimeter, keeping the cut close to the glass to preserve maximum adhesive thickness on the body for rebonding. This step requires patience and typically takes 15-20 minutes.
7. 7

   Remove glass from opening
   With the adhesive fully cut, position one person on each side of the glass (preferably one inside, one outside). Apply suction cup handles to the exterior glass surface. Carefully push the glass outward from inside while the exterior person supports and guides it. Lift the glass up and away from the vehicle. Immediately place it on a padded surface, leaning it at a safe angle.
8. 8

   Clean adhesive from body pinch weld
   Using a sharp utility knife, trim the old urethane adhesive on the body pinch weld down to approximately 1-2mm thickness. Do not remove all adhesive down to bare metal - leave a smooth, clean base layer for the new adhesive to bond to. Remove any loose debris, then clean the surface with isopropyl alcohol and allow to dry completely. Inspect the pinch weld for rust or damage and address if necessary.
9. 9

   Prepare new or existing glass
   If reusing the original glass, remove all old adhesive from the glass edge using a razor blade, leaving only the ceramic frit band. Clean the glass perimeter thoroughly with isopropyl alcohol. If installing new glass, ensure it is clean and free of contaminants. Apply glass primer to the ceramic frit band according to the adhesive manufacturer's instructions (typically a thin, even coat allowed to dry for 5-10 minutes).
10. 10

    Apply urethane adhesive
    Load the urethane adhesive cartridge into the application gun. Apply a continuous bead of adhesive to the body pinch weld, maintaining a consistent triangular or V-shaped bead approximately 8-10mm wide and 10-12mm tall. The bead should be uniform around the entire perimeter with no gaps or thin spots. Work quickly once adhesive application begins, as working time is typically 15-20 minutes.
11. 11

    Install rear window glass
    With assistance, carefully lift the glass into position using suction cup handles. Align the glass with the reference marks made during removal. Lower the glass into the opening, seating it firmly into the adhesive bead. Apply steady, even pressure around the entire perimeter to ensure full contact with the adhesive. The glass should sit flush with the body contour.
12. 12

    Set and secure glass position
    Once the glass is properly positioned, apply additional pressure to compress the adhesive bead to approximately 3-6mm thickness. Use masking tape strips across the glass to body in several locations to hold the glass in position during curing. Check alignment from multiple angles and make any minor adjustments within the first 5 minutes before adhesive begins to set.
13. 13

    Install weather stripping
    If the weather stripping was removed intact and in good condition, press it back into position around the window perimeter. If installing new weather stripping, clean the mounting surfaces and install according to the seal design (press-fit channel or adhesive-backed). Ensure complete sealing around the entire perimeter.
14. 14

    Reinstall interior trim
    Reconnect any speaker or harness connections to the interior trim panel. Align the trim panel with its mounting points and press into place to engage retention clips. Install all Torx fasteners that were removed during disassembly. Reinstall the rear package shelf or speaker grille if equipped, securing with the original fasteners.

Reassembly

1. Allow urethane adhesive to cure for minimum 4 hours before removing support tape
2. Do not drive the vehicle or slam doors for at least 4 hours; full structural cure requires 24 hours
3. Verify all interior trim panels are fully seated with no gaps or rattles
4. Test for water leaks after full cure by gently spraying water around the window perimeter

Verification

• Inspect the window perimeter from both inside and outside for uniform adhesive contact with no gaps or voids
• Check that the glass sits flush with the body contour and aligns with adjacent body panels
• Verify weather stripping is fully seated with no exposed gaps
• After cure time, perform a water leak test with gentle spray around all edges
• Confirm all interior trim is reinstalled securely with no loose fasteners or panels

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