Windshield

Remove and replace the windshield on a 2005 Dodge Viper, including cowl cover removal, wiper assembly removal, urethane adhesive removal, and new windshield installation with proper adhesive curing time.

Warnings

Tools required

Parts

• Windshield glass with third visor frit band × 1 — OEM Mopar or equivalent DOT-certified windshield
• Automotive urethane adhesive (fast-cure or standard) × 1 — Mopar windshield urethane or equivalent
• Urethane primer × 1 — Black urethane primer for glass and pinchweld
• Wiper arm nut cover caps × 2 — If damaged during removal
• Cowl cover clips × 1 — Replace any damaged clips
• Windshield molding clips × 1 — If equipped and damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 2 minutes for airbag system discharge
3. Cover both front fenders and hood leading edge with protective blankets to prevent scratches
4. Cover the dashboard with a clean drop cloth to catch any glass or debris
5. Inspect new windshield for damage, proper fit, and correct part number before beginning removal
6. Allow vehicle to reach ambient temperature if it has been in extreme heat or cold to prevent glass stress during removal

Procedure

1. 1

   Remove wiper arms
   Lift each wiper arm away from the windshield to the service position. Pry off the plastic nut cover cap at the base of each wiper arm. Using a socket, remove the wiper arm retaining nut from each side. Mark the position of each wiper arm on the wiper post with tape or marker for proper reinstallation alignment. Rock the wiper arms gently while pulling away from the cowl to release them from the splined posts. Remove both wiper arms completely.
2. 2

   Remove cowl cover assembly
   Open the hood. Locate and remove the Torx fasteners securing the cowl cover panel (typically along the rear edge near the windshield base). Release the plastic clips securing the cowl cover by carefully prying with a trim tool. The Viper cowl cover typically has clips on each side. Lift the cowl cover assembly up and away from the windshield base, disconnecting any washer hoses if attached. Set the cover aside in a protected area.
   ℹ️Cowl clips are brittle and may break. Have replacement clips available before beginning.
3. 3

   Disconnect windshield washer hoses
   Locate the windshield washer nozzles and hoses at the base of the windshield or under the cowl area. Disconnect the washer hoses from the nozzles by pulling firmly or releasing the retaining clips. If the nozzles are bonded to the windshield or cowl, they will be replaced during installation.
4. 4

   Remove interior rearview mirror
   If the rearview mirror is mounted to a button bonded to the windshield, slide the mirror assembly upward or release the set screw (depending on mount type) to detach it from the button. The button will remain bonded to the old windshield. If mirror removal is not possible without risking damage, protect it with masking tape and work carefully around it. Mark the mirror button position on the outside of the windshield with tape for proper placement on the new glass. Note: Verify whether the windshield is equipped with any embedded antenna or defroster elements before removal. Note: the 2005 Viper is not equipped with a rain sensor. Disconnect any such components carefully if present.
5. 5

   Remove A-pillar trim panels
   On both sides of the vehicle, if equipped with removable A-pillar interior trim, carefully pry the panels away starting from the bottom and working upward. These panels typically use plastic clips. Pull the panel away from the pillar to release all clips. Disconnect any electrical connectors if present. Remove both A-pillar trims completely to access the windshield edges. Note: the 2005 Viper is not equipped with side curtain airbags, so no A-pillar airbag components should be present.
6. 6

   Protect and prepare for glass removal
   Apply masking tape around the perimeter of the windshield on the exterior paint approximately 2 inches from the glass edge to protect the paint from knife damage. Apply tape to the interior dash edge along the windshield base. Have an assistant ready with suction cups. Verify the workspace is clear and safe for glass removal.
7. 7

   Cut urethane adhesive and remove windshield
   From inside the vehicle, use a cold knife or urethane cut-out knife to carefully cut through the urethane bead between the glass and the pinchweld. Start at one corner and work around the entire perimeter, keeping the blade angle toward the glass to avoid damaging the pinchweld. Once the adhesive is cut around the entire perimeter, have your assistant apply suction cups to the exterior of the windshield. Both operators should carefully lift and remove the windshield, tilting the top outward first, then lifting it up and away from the vehicle. Set the old windshield aside in a safe location.
   ⚠️The windshield may release suddenly once the urethane is fully cut. Maintain firm grip with suction cups at all times.
8. 8

   Clean and prepare pinchweld
   Using a utility knife with a fresh blade, carefully remove the old urethane from the pinchweld, leaving a smooth base layer approximately 1-2mm thick if the old urethane is in good condition. If the old urethane is contaminated or damaged, remove it completely down to bare metal. Remove any rust, loose paint, or debris from the pinchweld. Use a vacuum or compressed air to remove all dust and particles. Wipe the entire pinchweld with isopropyl alcohol on a clean rag and allow to dry completely. Inspect for rust or damage; repair any corrosion or dents before proceeding.
9. 9

   Prepare new windshield
   Unpack the new windshield and inspect for damage. Clean the ceramic frit band (black border) on the new windshield with isopropyl alcohol and allow to dry. If a mirror button needs to be bonded, position it using the alignment marks made earlier and bond it per adhesive manufacturer instructions (typically with a two-part epoxy), allowing it to cure before installation.
10. 10

    Apply primer to pinchweld and glass
    Apply urethane primer to the cleaned pinchweld using the applicator provided with the primer. Apply a thin, even coat around the entire perimeter. Apply urethane primer to the ceramic frit band on the new windshield where the urethane will bond. Follow the primer manufacturer's specified open time (typically 5-15 minutes) before applying urethane adhesive.
11. 11

    Apply urethane adhesive
    Load the urethane adhesive cartridge into the caulking gun. Apply a continuous bead of urethane around the entire pinchweld perimeter. The bead should be triangular in cross-section, with the base on the pinchweld, approximately 10-15mm wide and 10-15mm tall. Maintain consistent bead size and avoid gaps. Work quickly but carefully, as urethane begins to skin over within minutes.
12. 12

    Install new windshield
    Place windshield setting blocks on the pinchweld at the bottom center and lower corners to ensure proper glass height and centering. With your assistant, lift the new windshield using suction cups and carefully position it above the opening. Align the windshield with the body opening, ensuring equal gaps on both sides. Lower the glass onto the setting blocks, seating it firmly into the urethane bead. Press around the entire perimeter from the outside to ensure full contact between the glass and urethane. Check alignment from all angles. Once positioned correctly, apply masking tape across the windshield to the body at several points to prevent movement during curing.
    ⚠Once the windshield contacts the urethane, repositioning becomes very difficult. Ensure proper alignment before full seating.
13. 13

    Clean excess urethane and install moldings
    Use a damp cloth to remove any excess urethane that has squeezed out around the perimeter before it cures. If the vehicle is equipped with exterior windshield moldings or reveal moldings, install them now by pressing them into place over the glass edge or pinchweld, ensuring all clips engage properly. Reconnect windshield washer hoses to nozzles.
14. 14

    Reinstall interior trim and accessories
    Reinstall both A-pillar trim panels, ensuring all clips seat properly and reconnecting any electrical connectors for speakers or sensors. Reinstall the rearview mirror assembly onto the bonded button (if cured). Ensure the mirror is securely attached.
15. 15

    Reinstall cowl cover and wiper arms
    Position the cowl cover assembly back onto the vehicle, engaging all clips and fasteners. Install and tighten the Torx fasteners securing the cowl cover. Reinstall both wiper arms onto the splined posts, aligning them with the position marks made during removal. Install the wiper arm retaining nuts and tighten securely. Snap the plastic nut cover caps back into place.
16. 16

    Reconnect battery and test systems
    Reconnect the negative battery cable. Test the windshield washer system for proper operation and check for leaks at all hose connections. Test the wiper system to verify proper arm positioning and operation. Inspect the windshield installation from all angles for proper seating, alignment, and no visible gaps in the urethane seal.

Reassembly

1. Allow urethane to cure per manufacturer specifications before driving (typically 1 hour minimum for safe drive-away with fast-cure adhesive, 24 hours for full structural cure with standard adhesive)
2. Remove all masking tape from paint and glass after urethane has skinned over (typically 1-2 hours)
3. Avoid car washes and high-pressure water for 48 hours after installation
4. Do not slam doors forcefully for the first 24 hours as this can create pressure that may unseat the windshield

Verification

• Visually inspect the windshield from outside for proper centering with equal gaps on both sides and correct positioning top to bottom
• Inspect the urethane seal from inside the vehicle for continuous contact with no gaps or voids
• Test windshield washer system for proper spray pattern and no leaks
• Test wiper system for proper operation with no interference or unusual noise
• Check for wind noise or water leaks during initial test drive (after appropriate cure time)
• Verify all interior trim panels are secure with no rattles
• Verify rearview mirror is securely attached and properly positioned

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