Auto GlassTechnical InstituteAuto GlassTechnical Institute

For more information or to register for a class, please visit www.glass.org or call 866/DIAL NGA (342-5642), ext. 134.

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A. Windshield Preparation

1. Cover the front seats, floorboards, dash and steeringwheel with a clean drop cloth or disposable plastic covers.Note: Always wear eye and hand protection when working withglass. Make sure that you have the right glass and the ure-thane systems are current. Windshield part numbers areFW02724, FW02723, FW02722 or FW02721.

2. Remove the rearview mirror by loosening the Tork screwusing a T-20 Tork screwdriver. Slide the wire-harness trim coveroff the headliner. Slide the mirror off the mirror bracket in anupward motion.

3. Disconnect the wire harness from the underside of thehardware with a small flat-tip screwdriver or your fingernails.

4. Remove the windshield-wiper nuts using a wrench orsocket. If the nuts are tight, loosen them with a 14-millimeterwrench and then come back with your socket. Move the wiperarm in an up-and-down motion to break it loose from the post,or use a wiper puller. Caution: Wipers can sometimes be hardto remove. To avoid stressing the post, use a wiper puller. Thewipers are marked; take note to ensure proper re-installation.

5. Using a No. 2 Phillips-tip screwdriver, remove the twoplastic screw inserts on the fasteners located on the outeredge of the cowling corners. There is one on the passenger’sside and one on the driver’s side.

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2007-08 Toyota Tundra Crew Cab By Gilbert R. Gutierrez

Vehicle type: Four-door, crew-cab pickup truck

NAGS numbers*: Windshield part numbers are FW02724,FW02723, FW02722 or FW02721; front door glass FD23323-24 R-L; rear door glass FD23325-26 R-L; and back glassFY95054, FY95053, FB23336, FB23335 and FB23334.

Helpful tools or supplies: Retention tape or a rubber hose toprotect the fenders and hood; a PryBaby for molding andpanel removal.

Watch for: Be careful not to pull too hard on the rearview mir-ror harness during removal to avoid ripping the headliner.When removing or re-installing the A-pillar trim panels, takecare to avoid disturbing the curtain air-bag harness.

*With permission from National Auto Glass Specifications.Call NAGS at 800/551-4012 or visit www.nags.com.

Vehicle information

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6. Remove the rubber corner pieces from the corners of thecowling at the base of the windshield. Using an outwardmotion, pull out the rubber piece, and then gently pull the rub-ber insert from the cowling.

7. With the hood open, push in and pop loose the six plastictab fasteners using a No. 1 PryBaby tool from the underside.There are three on the passenger’s side and three on the dri-ver’s side, with a guide pin at the center.

8. Remove the two-part cowl by sliding it in an upward-out-ward motion toward the engine compartment, disengaging theeight underside tabs on the front part of the cowling from thebase of the windshield. Tape the hood and fender with mold-ing-retention tape to avoid gnarling or scratching the cowling.

Note: When re-installing the cowling, use a No. 1 PryBaby toolto assist in the installation of the cowling onto the bottom ofthe windshield.

9. If using a cold knife or power tool to cut out the glass,remove the A-pillar trim panels, as the windshield fits close tothe pinchweld.

10. Remove the door weatherstrip.11. Remove the screw covers using a No. 2 PryBaby. 12. Remove the two 10-millimeter bolts hidden beneath the

covers using a 10-millimeter socket-wrench driver. Pull the han-dle loose.

13. Remove the A-pillar trim panels using a door-panelremover or No. 2 PryBaby tool. Caution: Be careful not to dis-

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turb the curtain air-bag harness when removing or re-installingthe A-pillar trim panels. Note: Before beginning windshieldremoval, verify the new windshield is the correct one and theurethanes and primers are current. Never use outdated prod-ucts as this could jeopardize the structural integrity of the vehi-cle and the safety of its passengers.

Removal14. Make sure cutting blades are sufficiently sharp.15. Before cutting out the windshield, remove contaminants

from the glass and pinchweld to prevent contact with the urethane.16. If using a cold knife, use a 3⁄4-inch blade. Cut three sides;

then use a long knife or power tool to cut the bottom of the wind-shield. Note: There are no gravity stops on this windshield.

17. If trying to save the windshield, use an Equalizer with an8-inch blade. Note: When using any power tool, lubricate thecutting area with water. Spray the top and sides; then makeyour cuts.

18. After cutting the sides and top, cut out the bottom por-tion of the glass using an Equalizer Express. Spray the bottomof the windshield with water at least 4-to-5 inches above theurethane on the glass, so the water flows down into the ure-thane while you make your final cut across the bottom of thewindshield. Caution: Never use your head to push, as thiscould result in back and neck injuries.

19. Take the windshield out of the opening using a set ofvacuum cups. Lift the glass and place it on a windshield standor suitable workstation.

Installation20. After cutting the windshield out, remove contaminants

such as dirt, moisture and other debris from the pinchweld.Clean the dashboard.

21. Dry fit the new glass to the opening. Mark your glassusing a grease pencil or molding-retention tape.

22. Place your vacuum cups on the windshield in the appro-priate location for a one-person set.

23. For driver-side setting of the windshield using a GlassHandler Kit, place the kit’s elbow-setting pad on the driver’sside of the hood area; then lift the windshield from the standusing the vacuum cups.

24. Reach over, place your elbow on the setting pad and setthe windshield onto the old urethane.

25. With the windshield resting in the opening, make sure itis in the right spot.

26. Adjust both sides to the correct setting, marking thepassenger’s side, then the driver’s side. Lift the glass andplace it on a windshield stand or suitable workstation.

27. Follow the urethane manufacturer’s recommendationsfor installation.

28. Clean the inside of the windshield using a urethanemanufacturer-recommended product; follow recommendedsteps. Note: Do not touch the bonding area of the windshieldafter cleaning, prepping or priming it.

29. Wear powder-free Nitrile gloves to keep off chemicals.30. Apply the glass prep and primer, following the urethane

manufacturer’s recommendations.

31. Using a pinchweld-preparation tool, remove as much ofthe original urethane as the urethane manufacturer recom-mends. Note: Before removing the old urethane, make surethere are no contaminants and do not touch the pinchweldafter you have prepped the area.

32. Apply the pinchweld primer only to the areas whereneeded, and follow the urethane manufacturer’s recommenda-tions. Allow preps and primers to dry as recommended by theurethane manufacturer.

33. Apply a triangular bead of urethane to the same path asthe freshly cut urethane on the pinchweld. Note: Before cuttingyour V-notch with a Top Notch tool, cut the tip off of your nozzlewith a nozzle cutter. With the cut nozzle, measure to the top ofthe roofline, and at 1⁄16 inch higher than the roofline, make a markon the nozzle with a pen or marker. Notch the nozzle up to themarked line; this will give you the appropriate triangular bead.

34. Lift the windshield from the windshield stand or worksta-tion using vacuum cups. Reach over, place your elbow on thesetting pad and set the windshield on the urethane at the markyou made during dry fit. Lower the driver’s side of the wind-shield onto the urethane and line it up with the dry-fit mark; it isnow in place.

35. The windshield is now ready to be decked. Press firmlyto ensure a good seal.

36. Before re-installing the parts, check for leaks. Use a leakdetector to go over the perimeter of the windshield. If you finda leak, apply pressure to the spot to ensure the glass makescontact with the wet urethane.

37. Re-install the removed parts in reverse order.38. Allow the urethane to cure according to the urethane

manufacturer’s recommended cure time before returning thevehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends couldjeopardize the structural integrity of the car and the safety of itspassengers.

39. You have completed the removal and replacement ofthe windshield.

B. Front door glass Removal

1. Make sure you have the right glass. Front door glass partnumbers are FD23323-24 R-L.

2. To remove the door panel, pry off the trim cover on thedoor-handle assembly using an installation stick or a No 2PryBaby.

3. Remove the No. 1 Phillips screw behind the trim cover.

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4. Remove the trim cover from the armrest-pull handle usinga small flat-tip screwdriver or a rubber hook tool.

5. Remove the No. 1 Phillips screw beneath the trim cover. 6. Pop loose and remove the door-mirror trim cover using

an installation stick or No. 1 PryBaby tool.7. To remove the push-in plug fasteners from the front side

of the trim panel, use a rubber hook tool to push the centerpush-in plug in. Get behind the panel with a No. 3 PryBabytool, and use your fingers to remove the fastener.

8. Open the door-panel compartment, slip in an installationstick from the underside of the electrical window-switch assem-bly and gently push up to disengage the assembly. Disconnectthe electrical window-switch assembly harness by pinching the

tab and pulling the harness free.9. Pop loose the trim panel using a door-panel remover or use

a No. 2 PryBaby tool to disengage the eight plastic fastenerslocated about 12-to-14 inches from the top of the door panel.

10. In an upward-outward motion, gently pull the door paneland disengage it from the door.

11. Disengage the door-handle assembly by pulling the twocable ball joints from the lock (a white plastic piece) and doorhandle assembly (a green plastic piece) away from the panel.

12. Disconnect the light-assembly harness by pinching thetab and pulling the harness free.

13. Set the door panel in a safe place. 14. Remove the plastic sound-weather barrier.

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15. Remove the four 10-millimeter bolts from the speakerand put aside; this will give you access to the front plasticglass retainer.

16. Lower the glass to align the mounting hardware withthe opening.

17. Remove the two 10-millimeter bolts on the plastic glassretainers. There is one on the front of the door and one on therear, on the regulator arms.

18. Remove the glass by lifting the backside first to disen-gage it from the weatherstrip channel.

Replacement19. To replace the door glass, slip it back into the door in the

same manner you removed it. Make sure it is fully in the weather-strip channel and not on the backside of the metal carrier. Alignthe carrier before bolting it to the plastic hardware on the glass.

20. Check the operation of the glass before replacing thepanel to ensure proper installation.

21. Re-install the removed parts in reverse order. 22. You have completed the removal and replacement of

the front door glass.

C. Rear door glassRemoval

1. Make sure you have the right glass. Rear door glass partnumbers are FD23325-26 R-L.

2. To remove the door panel, pry off the trim cover on the door-handle assembly using an installation stick or a No 2 PryBaby.

3. Remove the No. 1 Phillips screw behind the trim cover. 4. Remove the trim cover from the armrest-pull handle using

a small flat-tip screwdriver or a rubber hook tool. 5. Remove the No. 1 Phillips screw beneath the trim cover. 6. Pop loose and remove the upper-door rear-side trim cover

using an installation stick or plastic door-panel removal tool.7. To remove the push-in plug fasteners from the rear side of

the trim panel, use a rubberhook tool to push the centerpush-in plug in. Get behind thepanel with a No. 3 PryBaby tool,and use your fingers to removethe fastener.

8. Slip in an installationstick from the underside ofthe electrical window-switchassembly and gently push upto disengage the assembly.Disconnect the electrical window-switch assembly harness bypinching the tab and pulling the harness free.

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9. Pop loose the trim panel using a door-panel remover or aNo. 2 PryBaby tool to disengage the nine plastic fastenerslocated about 12-to-14 inches from the top of the door panel.

10. In an upward-outward motion, gently pull the door paneland disengage it from the door.

11. Disengage the door-handle assembly by pulling the twocable ball joints from the lock (a white plastic piece) and door-handle assembly (a green plastic piece) away from the panel.

12. Disconnect the light-assembly harness by pinching thetab and pulling the harness free.

13. Disconnect the speaker-assembly harness by pinchingthe tab and pulling the harness free.

14. Set the door panel in a safe place.

15. Remove the plasticsound-weather barrier.

16. Lower the glass toalign the mounting hardwarewith the opening.

17. Remove the two 10-millimeter bolts from the plas-tic glass retainer. There is oneat the front and another at therear of the door.

18. Raise the glass all theway to the “up” position.

19. Remove the two 10-millimeter bolts from the glass-chan-nel run. There is one at the top and another at the midsectionof the door.

20. Break loose the foam at the top of the glass-channelrun. Disengage the glass-channel run and slip it out of the doorthrough the lower opening. Note: When re-installing the glass-channel run, use a glass cleaner as a lubricant.

21. Lower the glass manually.22. Remove the glass by lifting the backside first to disen-

gage it from the weatherstrip channel. Slip it through the inner-side of the doorframe between the weatherstripping and thecutout notch at the top of the frame.

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Replacement23. To replace the rear door glass, slip it back into the door

in the same manner you removed it. Make sure it is fully in theweatherstrip channel and not on the backside of the metal car-rier. Align the carrier before bolting it to the plastic hardware onthe glass.

24. Check the operation of the glass before replacing thepanel to ensure proper installation.

25. Re-install the removed parts in reverse order. 26. You have completed the removal and replacement of

the rear door glass.

D. Back glass Removal

1. Make sure you have the right glass. Back glass part num-bers are FY95054, FY95053, FB23336, FB23335 or FB23334.

2. Remove the two push-in, pull-out cargo-net posts bypulling the outer post to the second stage. There is one on thedriver’s side and one on the passenger’s side.

3. Remove the two-part trim panel using a No. 3 PryBabytool or panel remover. You can also remove it by slightly pullingon it. There are five push-in fasteners and six guide pinsaround the passenger’s side panel, and nine push-in fastenersand three guide pins around the driver’s side panel.

4. In an upward-outward motion, gently pull the rear-cabpanels to disengage them from the upper weatherstrip.

5. Set the back glass trim panels in a safe place. 6. Remove the speaker box behind the trim panel using a

10-millimeter socket wrench to remove the three bolts. 7. Disconnect the speaker harness by pinching the tabs

together.8. Use a 10-millimeter socket to remove the bolt beneath

the motor harness. 9. Disconnect the back glass motor harness by pinching the

tabs together and pulling the harness free.

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10. Remove the metal trim cover for the opening that housesthe back glass. There are 12, 10-millimeter bolts that hold thiscover to the cab and one plastic push-in fastener to assist in lin-ing up the metal trim cover. Use a 10-millimeter socket toremove the bolts and a door-panel remover to remove the plas-tic push-in fasteners. If they are not too tight, just slip the panelloose from the plastic push-in fasteners.

11. Disconnect the two electrical connectors from thedefroster post on the right side of the back glass. Make surethey go back on the same way they came off.

12. Lower the glass to align the mounting hardware withthe opening.

13. Remove the four 10-millimeter bolts on the metal carrier

that hold the plastic glass retainers. There are two on the leftside of the electric lifts and two on the right side.

14. Remove the inner weatherstripping using a No. 3PryBaby tool.

15. Remove the glass by lifting the backside first to disen-gage it from the weatherstrip channel. Slip the glass to theouter-side of the back glass frame.

Replacement16. To replace the back glass, slip it back into the cab in the

same manner you removed it. Make sure it is fully in the weather-strip channel and not on the backside of the metal carrier. Alignthe carrier before bolting it to the plastic hardware on the glass.

17. Check the operation of the glass before replacing thepanel to ensure it operates properly.

18. Re-install the removed parts in reverse order. 19. You have completed the removal and replacement of the

back glass.

The author is senior technical adviser forEqualizer Industries Inc., Round Rock, Texas.Write him at ggutierrez@equalizer.com. A spe-cial thanks to Equalizer President Eric Asberyfor providing the vehicle.

Notes:

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