2004 Chrysler Pacifica FWDFACTORY OEM SERVICE PROCEDURE

Body Glass System: Windshield: Installation

Refer to the Safety Precautions in this section for description of tools and adhesive systems that are recommended for use in this procedure. (Refer to WARNING  ).

The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle.

Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended.

CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use.
To avoid stressing the replacement windshield, the urethane bonding material on the windshield fence should be smooth and consistent to the shape of the replacement windshield. The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening.
  1. Place replacement windshield into windshield opening and position glass in the center of the opening against the compression spacers.
  2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass.
  3. Remove replacement windshield from windshield opening.
  4. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig 1 ).
    Fig 1: Identifying Work Surface Set Up And Molding Installation
    G03571818Courtesy of DAIMLERCHRYSLER CORP.
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.