Windshield

Complete removal and replacement of the windshield glass assembly on a 2008 Dodge Viper, including cowl panel and wiper system removal for access.

Warnings

Tools required

Parts

• Windshield glass × 1 — Use OEM specification
• Automotive urethane adhesive × 1 — Mopar or equivalent DOT approved
• Windshield primer × 1 — Compatible with urethane adhesive system
• Cowl panel clips (if damaged) × 1 — Mopar cowl panel retainer clips
• Windshield molding clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and ensure engine is cool
2. Disconnect negative battery cable to prevent wiper motor activation during service
3. Cover hood and fenders with protective blankets to prevent damage during glass removal
4. Remove windshield wiper arms by lifting protective cap, removing retaining nut, and rocking arms off splined shaft
5. If replacing windshield due to damage, tape the interior side of glass to minimize shattering during removal
6. Verify replacement windshield is correct part number and inspect for shipping damage before beginning removal

Procedure

1. 1

   Remove cowl panel assembly
   Open the front clamshell hood. Locate and remove the fasteners securing the cowl/wiper access panel at the base of the windshield. Fastener count, type, and locations must be verified against the factory service manual for the 2008 Viper as this platform uses a composite body and non-standard cowl arrangement. Release any retaining clips by gently prying with trim tools. Disconnect the washer hose from the spray nozzles if integrated into the cowl. Lift the cowl panel assembly away from the vehicle to expose the windshield lower edge and wiper assembly.hicle to expose the windshield lower edge and wiper motor assembly.
2. 2

   Remove windshield molding and trim
   Carefully remove the outer windshield molding if equipped. On the Viper, this may be minimal or integrated into the glass assembly depending on build configuration. Use trim tools to release any clips securing exterior trim pieces. Work carefully to avoid breaking clips as they may become brittle with age. Set aside all trim pieces in order for reinstallation.
3. 3

   Cut urethane adhesive around windshield perimeter
   Working from inside the vehicle, use a cold knife windshield cutting tool to slice through the urethane adhesive bonding the windshield to the pinchweld. Start at a lower corner and work around the entire perimeter, maintaining consistent depth to cut through the adhesive without damaging the pinchweld surface. Keep the blade angle shallow to avoid cutting into the dashboard or A-pillar trim. This step requires patience; forcing the blade can break the glass or damage the body.
4. 4

   Remove windshield glass from vehicle
   With a second person assisting, attach suction cup holders to the exterior surface of the windshield. Gently push the windshield outward from inside the vehicle while the assistant supports and guides it from outside. Lift the windshield up and away from the vehicle once free. Place it in a safe location on padded surface or immediately dispose of if damaged. Never attempt to remove windshield glass alone; the size and weight require two people for safe handling.
5. 5

   Clean and prepare pinchweld surface
   Remove all remaining urethane adhesive from the body pinchweld using a utility knife and non-metallic scraper. Leave a thin (1-2mm) layer of original urethane as a bonding base for the new adhesive. Do not scrape down to bare metal unless corrosion or damage requires it. Remove any glass fragments or debris from the pinchweld channel. Clean the prepared surface with isopropyl alcohol and allow to dry completely. Inspect the pinchweld for rust or damage; address any corrosion with appropriate rust treatment before proceeding.
6. 6

   Prepare new windshield glass
   Remove the new windshield from protective packaging and inspect the glass for any damage. Verify that any pre-attached moldings, brackets, or rain sensor mounts are properly positioned. Clean the ceramic frit band (black edge) of the new windshield with isopropyl alcohol where urethane will be applied. Allow to dry completely. Apply windshield primer to the frit band per primer manufacturer instructions, typically a thin even coat around the entire perimeter. Allow primer to flash off per manufacturer specifications (usually 5-15 minutes).
7. 7

   Apply primer to vehicle pinchweld
   Apply windshield primer to the prepared pinchweld surface on the vehicle using the primer pen or applicator. Ensure even coverage on all surfaces where new urethane will bond. Allow primer to flash according to manufacturer instructions. Do not touch primed surfaces with bare hands as oils will compromise adhesion.
8. 8

   Apply urethane adhesive
   Load the urethane adhesive cartridge into the dispensing gun. Cut the nozzle to achieve a bead width appropriate for the application (typically 10-12mm for windshield installation). Apply a continuous, even bead of urethane around the entire perimeter of the windshield on the primed frit band. The bead should be triangular in cross-section, with adequate height (typically 10-15mm) to ensure proper compression when glass is installed. Work quickly but carefully; urethane begins to skin over within minutes depending on temperature and humidity.
9. 9

   Install windshield glass
   With an assistant, position the new windshield above the opening, ensuring correct orientation (top edge has less curve than bottom, and any rain sensor or mirror mount faces interior). Align the windshield with the body opening and the cowl panel mounting area. Carefully lower the glass into position, seating it evenly onto the urethane bead. Apply firm, even pressure around the entire perimeter to compress the urethane and achieve proper bonding. The urethane should compress to approximately 2-3mm final thickness. Check that glass is seated evenly with no gaps and is flush with the body contour.
10. 10

    Secure and cure windshield
    Use masking tape or retention straps across the windshield surface to hold it in position during the initial cure if needed (typically not required if urethane was properly applied). Check for proper glass alignment from all angles. Wipe away any urethane that squeezed out onto painted surfaces immediately using a clean rag dampened with isopropyl alcohol. Verify the windshield is properly seated by checking the reveal (gap between glass edge and body) is consistent around the entire perimeter. Allow urethane to cure per adhesive manufacturer specifications before reinstalling components or moving vehicle. Minimum safe drive-away time is typically 1-4 hours depending on product and environmental conditions.
11. 11

    Reinstall cowl panel and wiper components
    Once urethane has achieved sufficient cure for component installation (check adhesive specifications), reconnect the windshield washer hoses to the spray nozzles. Position the cowl panel assembly over the windshield base and align all mounting points. Install cowl panel retaining clips and Torx fasteners, tightening evenly. Do not overtighten plastic fasteners. Reinstall the windshield wiper arms onto the splined shafts in their original positions, ensuring proper park position. Install the retaining nuts and protective caps.
12. 12

    Reinstall exterior trim and moldings
    Install any exterior windshield moldings or trim pieces removed during disassembly. Ensure all clips are properly seated and trim is flush with glass and body surfaces. Replace any damaged clips with new parts.

Reassembly

1. Reconnect negative battery cable
2. Test windshield wiper operation to verify proper arm positioning and spray pattern
3. Test windshield washer spray pattern and adjust nozzles if necessary
4. Inspect the windshield perimeter for any urethane gaps or insufficient bonding; address immediately if found
5. Clean windshield glass inside and out to remove any adhesive residue or fingerprints

Verification

• Visually inspect windshield installation from all angles to verify even reveal and proper seating
• Check for air leaks by running hand along windshield perimeter or using leak detection spray (after full cure)
• Perform a water test using a garden hose to check for leaks around the entire windshield perimeter (only after minimum cure time has elapsed)
• Verify windshield wiper operation across full range of motion without interference
• Check that windshield washer spray pattern hits the glass properly
• Verify rain sensor or mirror mount bracket functionality if equipped
• Confirm vehicle can be driven safely per adhesive cure time specifications before releasing to customer

More procedures for this vehicle