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Rear Window Defogger Grid Terminal Repair

WARNING: This page is about a different car, the 2004 Dodge Grand Caravan, 2004 Dodge Caravan, and 2004 Chrysler Town & Country. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: THE REPAIR KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER WHICH MAY CAUSE SKIN OR EYE IRRITATION AND CAN BE HARMFUL IF SWALLOWED. USE WITH ADEQUATE VENTILATION. DO NOT USE NEAR FIRE OR OPEN FLAME THE CONTENTS CONTAIN FLAMMABLE SOLVENTS. KEEP OUT OF REACH OF CHILDREN.
  • DO NOT TAKE INTERNALLY, IF SWALLOWED INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY.
  • IF SKIN CONTACT OCCURS, WASH AFFECTED AREAS WITH SOAP AND WATER.
  • IF EYE CONTACT OCCURS, FLUSH WITH PLENTY OF WATER.

If the rear window defogger grid terminal(s) is damaged or separated from the rear window, the repair of the grid terminals is possible using the Mopar® Grid Line Repair Package or an equivalent.

  1. If the grid terminal(s) is broken and a portion of the terminal is still attached to the heating grid, remove the portion of the clip remaining in the wire harness connector(s).
  2. Mask the areas so the conductive epoxy can be extended onto the adjacent grid line(s) as well as the bus bar.
  3. Apply a thin layer of conductive epoxy to the area where the terminal(s) where fastened and to the adjacent grid line(s).
    NOTE: To prevent the terminal(s) from moving while the epoxy is curing, a wedge or clamp must be used.
  4. Apply a thin layer of conductive epoxy on the terminal(s) and properly orient the terminal(s) at the desired location(s).
    CAUTION: To prevent the glass from fracturing, do not allow the glass surface to exceed 204° C (400° F).
  5. Allow the epoxy to cure 24 hours at room temperature or use a heat gun with a 260° to 371° C (500° to 700° F) range for 15 minutes. Hold the heat gun approximately 254 mm (10 inches) from repaired area.
    NOTE: To ensure proper installation, do not attach the wire harness connector(s) to the terminal(s) until the epoxy is completely cured.
  6. After the conductive epoxy has properly cured, remove the wedge or clamp from the terminal(s), reconnect the wire harness connector(s) and verify operation of the rear window defogger.
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