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Home >> Chevrolet >> 2004 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Body & Frame >> Windows >> Stationary Window System >> Repair Instructions >> Windshield Replacement >> Removal Procedure

Removal Procedure

IMPORTANT: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim.
  1. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems.
  2. Remove the antenna if necessary. Refer to Fixed Antenna Replacement in Entertainment.
  3. Open the hood.
  4. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
  5. Remove the inside rearview mirror. Refer to Rearview Mirror Replacement .
    CAUTION: Refer to Defroster Outlet Caution in Cautions and Notices.
  6. Cover to protect the following parts from broken glass:
    1. Upper dash pad
    2. Defroster outlets and A/C outlets
    3. Seats and carpeting
  7. Remove the door sealing weatherstrip from the upper pinchweld flange.
    CAUTION: Refer to Glass and Sheet Metal Handling Caution in Cautions and Notices.
  8. Remove the 2 screws that retain the windshield frame filler panels.
    Fig 1: Locating Windshield Frame Filler Panel Screws
    GM311718Courtesy of GENERAL MOTORS CORP.
  9. Remove the frame filler panels.
    IMPORTANT: The windshield reveal molding fills the cavities between the body and windshield and can not be reused if stretched or damaged.
  10. The windshield reveal molding is a one piece molding.
    Fig 2: Windshield Reveal Molding
    GM378497Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Glass and Sheet Metal Handling Caution in Cautions and Notices.
  11. Grasp the lower corner of the windshield reveal molding by hand and slowly pull the reveal molding away from the windshield.

    If the windshield reveal molding will not release, use a utility knife in order to cut around the windshield in order to remove the windshield reveal molding.

    Fig 3: Using Utility Knife To Remove Reveal Molding
    GM379905Courtesy of GENERAL MOTORS CORP.
  12. Remove the windshield reveal molding.
  13. Remove the lower windshield supports (1) from the cowl panel, if equipped.
    Fig 4: Identifying Lower Windshield Supports
    GM326804Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Keep the cutting edge of the tool against the window.
  14. This will allow the urethane adhesive to be separated from the window.
    • Leave a base of urethane on the pinchweld flange.
    • The only suitable lubrication is clear water.
    • Use J 24402-A  , J 39032  or equivalent in order to remove the window.
    Fig 5: Separating Urethane Adhesive From Window
    GM71179Courtesy of GENERAL MOTORS CORP.
  15. Remove the windshield (1) from the vehicle with the aid of an assistant (2).
    Fig 6: Removing/Installing Windshield
    GM441419Courtesy of GENERAL MOTORS CORP.