Rear Window

This procedure covers the removal and installation of the rear window glass on a 2008 Dodge Viper coupe, including release of urethane adhesive and reinstallation with new sealant.

Warnings

Tools required

Parts

• Rear window glass × 1 — Use OEM specification
• Urethane windshield adhesive × 1 — Mopar or equivalent DOT approved
• Urethane primer × 1 — Specific to glass adhesive system
• Interior rear trim panel clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface in a warm, dry environment (ideally 70-80°F)
2. Cover the rear decklid and surrounding exterior body panels with protective blankets or towels to prevent damage
3. Cover the interior rear bulkhead area and seats with protective material
4. Have an assistant available for glass handling

Procedure

1. 1

   Remove interior rear trim panel
   Working from inside the vehicle, locate and remove the interior rear bulkhead trim panel. Remove the fasteners securing the panel (verify fastener type — could be Torx, Phillips, or push-clips — against the factory service manual for the 2008 Viper coupe; typically located along the upper and side edges). Carefully pull the panel away from the body, releasing any push-clip fasteners. Disconnect any electrical connectors for the third brake light if integrated into the trim. Set the panel aside in a protected area.
2. 2

   Disconnect third brake light
   Locate the third brake light (CHMSL) assembly and confirm its mounting location on the 2008 Viper coupe (verify whether it is mounted to the rear window, body, or rear fascia before proceeding). Disconnect the electrical connector from the back side (accessible with interior trim removed). Remove any fasteners securing the brake light housing to the glass or body. Carefully remove the brake light assembly and set aside.
3. 3

   Prepare glass for removal
   From the exterior, apply masking tape along the body panel edges surrounding the window to protect the paint. Attach glass suction cups to the exterior surface of the rear window, positioning them in the upper corners for best leverage. Have your assistant hold the suction cups to support the glass weight.
4. 4

   Cut urethane adhesive from interior
   Working from inside the vehicle, use a utility knife to carefully score the urethane bead along the edge of the glass where it meets the body pinch weld. Cut approximately 1/4 inch deep into the urethane, being careful not to scratch the glass or damage the body structure. Work around the entire perimeter to break the initial seal.
5. 5

   Cut urethane adhesive with removal tool
   Insert the urethane adhesive removal tool or piano wire into the cut you made in the urethane bead. Working with your assistant supporting the glass from the exterior, carefully work the cutting tool through the urethane adhesive around the entire perimeter of the window. Use a sawing motion, keeping the tool angled toward the glass to avoid damaging the body pinch weld. The goal is to leave approximately 1-2mm of urethane on the body for re-bonding.
6. 6

   Remove rear window glass
   Once the urethane is cut completely around the perimeter, have your assistant push gently outward on the glass from the interior while you support from the exterior with the suction cups. Carefully lift the window away from the vehicle and set it on a padded surface with the exterior side up. If reinstalling the original glass, place it in a safe location where it will not be damaged.
7. 7

   Clean and prepare body opening
   Remove the majority of the old urethane from the body pinch weld using a utility knife, leaving a thin base layer of 1-2mm if the original adhesive is in good condition. If the old urethane is contaminated or damaged, remove it completely down to bare metal and apply urethane primer per manufacturer instructions. Clean the bonding surface thoroughly with isopropyl alcohol and allow to dry completely. Inspect the pinch weld for damage or rust and repair as necessary.
8. 8

   Prepare new or existing glass
   If installing new glass, ensure any moldings or third brake light mounting provisions are transferred from the old glass. Clean the perimeter edge of the glass that will contact the urethane with isopropyl alcohol. Apply urethane primer to the glass edge according to the adhesive manufacturer's instructions (typically a thin coat, allowing 10-15 minutes to dry). Do not touch the primed surface.
9. 9

   Apply new urethane adhesive
   Load the urethane windshield adhesive into the caulking gun. Apply a continuous bead of fresh urethane adhesive around the entire perimeter of the body pinch weld. The bead should be approximately 3/8 inch wide and 3/8 inch tall, forming a triangular profile. Ensure there are no gaps or voids in the bead. Work quickly as urethane begins to skin over within minutes.
10. 10

    Install rear window glass
    With your assistant, position the glass above the opening using the suction cups. Align the glass carefully with the body opening, ensuring proper orientation (third brake light at top center). In one smooth motion, lower the glass into position, pressing firmly and evenly around the entire perimeter to seat the glass into the urethane. The glass should compress the urethane bead and make full contact with the pinch weld.
11. 11

    Verify seal and clean excess adhesive
    Inspect the urethane seal from both inside and outside the vehicle. You should see the urethane compressed against the glass around the entire perimeter with no gaps. If gaps are present, apply gentle pressure to those areas to seat the glass. Carefully remove excess urethane that has squeezed out using a plastic tool and clean rags. Do not disturb the primary seal. Remove masking tape from the body panels.
12. 12

    Reinstall third brake light and interior trim
    Reconnect the third brake light assembly and secure it with its fasteners. Reconnect the electrical connector. Reinstall the interior rear bulkhead trim panel by reconnecting any electrical connections, aligning the panel into position, and securing with the original fasteners and push-clips (verify fastener type against the factory service manual).

Reassembly

1. Allow urethane adhesive to cure for minimum 2 hours before moving vehicle (verify adhesive manufacturer's safe drive-away time)
2. Do not wash vehicle or expose window to water spray for 24 hours
3. Do not slam doors or stress the window for 48 hours while adhesive fully cures
4. Verify third brake light operation after completion

Verification

• Verify no gaps exist in the urethane seal around the entire perimeter of the window
• Check for proper glass alignment with body panels and consistent gap spacing
• Test third brake light function
• After cure time, inspect for water leaks by gently spraying water around the window perimeter
• Verify interior trim panel is secure and all clips are engaged

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