2026-02-27

Fixed Roof Glass (Model YL) (Remove and Replace)

Correction code 10200300102 FRT 2.70 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.

Remove

  1. Open all four doors and lower all four windows.
  2. Open the liftgate.
  3. Remove the rear headliner assembly from the vehicle. See Rear Headliner (Model YL) (Remove and Replace).
  4. Prepare WRD Spider 3 glass removal kit (1571168-00-A).
  5. Apply tape to the body surrounding the roof glass.
  6. Locate the datum at the left rear of the roof glass, slide the equalizer up against the datum, carefully cut through the adhesive around the roof glass, then separate the datum from the roof glass to assist in the cutting process.
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    Note
    You may not see the datum clearly, but you can feel it with the blade.
  7. Thread the nylon string through the wire starter to prepare for insertion.
  8. Insert the tool through the urethane seal at the rear corner of the roof glass.
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    Note
    Use a protective shield to avoid damaging the painted surfaces.
  9. Pull the nylon string through the seal. Ensure enough length of the nylon string to wrap around the entire perimeter of the glass. Keep both ends of the string inside the vehicle; they do not need to be fully pulled out.
  10. Route the nylon string around the glass perimeter, placing it under the seals.
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    Note
    Take care not to damage the seals of the front windshield or liftgate.
  11. Attach the anchor to the inside of the roof glass and secure the line to it for stability during the process.
  12. Follow the spider tool instructions to feed the nylon string through the tool’s opening and tie a knot to secure it.
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    Note
    Ensure the spindle is turned in the correct direction to avoid damaging the tool.
  13. Attach the spider cutting tool to the inside of the roof glass. Check the orientation of the cutting line, ensuring it wraps over the large pulley and maintains a 90-degree angle for proper operation.
  14. Secure the angle driver to the electric drill.
  15. Use the electric drill to cut the urethane around the roof glass.
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    Note
    During the operation, note the following:
    • Keep the cutting line positioned above the datum and roof brackets (x4) to prevent it from getting caught or damaged.
    • Suggest using a guard or trim tool to apply upward pressure on the line during cutting to ensure smooth operation.
    • If the line is caught, try pulling it backward to release it from beneath the metal roof bracket. If the line stays stuck, adjust by swapping the positions of the anchor and cutting tool.
  16. Detach and remove all tools, discard the used nylon string properly, and place all tools back into the kit.
  17. Attach the suction cups (x4) firmly to each corner of the roof glass, carefully lift and remove the roof glass from the vehicle, then detach the suction cups from the glass after placing it safely.
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    Note
    Recommend assistance to ensure safety and ease.
  18. Clean off the leftover glass adhesive from the body, ensuring the remaining urethane is no thicker than 1 mm.
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    Note
    Be cautious to avoid damaging the paint of the vehicle during cleaning.
  19. Remove and discard the rear location pin from the body.

Replace

  1. Pace the new roof glass on a support stand and prepare for installation by removing all protective films or adhesive covers from the glass, and checking all related accessories to confirm undamaged and complete.
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    Note
    Recommend assistance to ensure safety and ease.
  2. Wipe the urethane path on the body and roof glass with IPA and allow one minute for drying.
  3. Remove the tape from the body surrounding the roof glass.
  4. Apply the urethane primer along the urethane path on the body and roof glass and allow the primer to dry for two minutes before applying urethane.
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    Note
    If using Sika 258 sealant, ensure to use Sika Special Activator Pro, as shown in the orange item in the picture.
  5. Prepare the caulking gun with urethane.
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    Note
    The nozzle opening must be 12.5mm wide and 20mm tall.
  6. Apply urethane to the roof glass along the primer path, strictly following the specific dotted line route on the roof glass.
  7. Attach the suction cup (x4) to the roof glass and position it onto the vehicle, ensuring front and rear datums align with the body.
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    Note
    Recommend assistance to ensure safety and ease.
  8. Check and adjust the gap and flush of the roof glass according to current CVIS specifications, ensuring both left and right sides have identical parameters.
  9. Press the roof glass firmly onto the body once in position, using sandbags if needed.
  10. Apply tape to secure the roof glass in place.
  11. Remove the suction cups (x4) from the roof glass.
  12. Install the rear headliner assembly to the vehicle. See Rear Headliner (Model YL) (Remove and Replace).
  13. Close the liftgate.
  14. Raise all four windows and close all four doors.
  15. Reposition the windshield seal, spraying glass cleaner for lubrication if needed.
  16. Remove the tape securing the roof glass to the vehicle after the urethane has cured.
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    Note
    During the operation, note the following:
    • Follow the minimum curing time per adhesive manufacturer: Dow Betaseal Express requires at least 1 hour (temperature -18℃ or higher); Henkel and Sika require at least 8 hours (ideal conditions: 23℃, 50% relative humidity).
    • Park the vehicle indoors during curing.
    • If needed, apply tape to the glass, press to secure, and instruct the customer to remove it after 24 hours.
    • Advise the customer to avoid high-speed driving and speed bumps for the next 24 hours.