ine How pet pane » tools; Sy oc le Don iit 2 ‘Applicable Years: All ® Tob Ses yo ress » Tinwor » Idec to ote eke eae | ! | | ye of the most perplexing tasks to perform on the 911 is the removal of the window glass, whether its the front or rear window, or either of the know what you are doing. However, with a few ‘is ond stepby-siep instiuctions, the process i made much easier. A few of the projects in thie book require remav- ing ard replacing the wincow glass—replacna the Wield seal (Project 80, instalina a new dash pad (f0iee 67), ard replacing the: interior headliner (ect 8). The process of removal can be cuite "ky. 50 (ve dedicated an entire project tit ANI four major pieces of glass on the 911 coupe 28 atachectin 9 similar mariner. The front windshield weal asthe rear and two aide quarter windows are ‘4in pimarly by a rubber sea) that grabs both the Sestand ‘the chassis of the car. It's a very similar sys ‘St 0 the one used on the 386. The 911 cabriolet ‘arga have the same system for mounting the Toutting and securing the rear window. The rear 'S? Window installation le very difficult, and you should probably enlist the help of someone who has done it previously. Cn earlier 211s with rear pop-out windows, the process becomes even easier, 28 the glass and frame are cimply unscrowed from the car The first step in removing the glass isto carofully remove the widow molding from the car. The early cars were equipped with chrome. window molding that actually inserts into the glass seals. On the later cars, this trim was anodized aluminum. In either case, itis very easy to damage and destroy the molding when you ere removing it Forthe windshield, start bytakings meduum-sized serewdriver and siding the little maleing joining clos that are located on the top and bottom to the side. Don't scratch the molding with the screwdriver: Now, carefully gently pry up one part of the molding with: the screwdhiver. Work carefully, and make-sure not to. bbend the metal trim as you are removing is Ifthe trim isbent signficentl, then it will be nearly impossible 10 reinstall when youtry to replace the windshield Gently move around the perimeter of the mold- ing using the screwdriver to pry it up: Never take one ‘end of the molding and pull on it, as this can bend it beyend recovery. Just carefully inch the screwcriver around the molding, being very careful not to bend it Significantly. If you need any encouragement on hav- ing patianes, just keep. in mind that f you damage them, these two places are about $75 each to replace. The rear window and side window pieces are: leven more expensive to replace, so the key word hereis patience. If your trimis fading or damaged already, ‘then this would be an opportune time to replace it. ‘After you have removed all of the molding from your car, | recommend hanging it from the ceiling, Replacing the windshield or gjass is not 2 one-day ‘ask, and you don't want this very fragile melding just siting around whore things will pile on it. Make sure that itis tucked away ina very safe spot. New, the process of removirg the glass can begin. Take a razor blade or an X-acto knife, and ‘begin cutting through the seal where it mounts to the: ar, The point isto cut away the part of the seal that 1s holding the glass onto the frame of the car You ‘want to cut dovin the distinct groove inthe middle of theseal that normaly holds on the windew trim. Don't worry. about hitting anything underneath, as there isn't anything under the sea to worry about, with the ‘exception of the rear window, Make sure that you cut deeply through the seal, as it won't separate from the ‘ar ifit’s not completely separated, The process of cutting the seal takes a bit of patience, and there is a tendency to want to rush the Jeb. However, you should make sure that you proceed Carefully, a8 the old windshiolds are often very brittle and break much more easiy than new ones, When you get to.a point where the seal starts to separate completely and you car grab itwith your hands, you can usualy tear the seal out of the aroove after sco ing it with the knife. Gently pull on the seal, and it should rip itself and tear anay from the car, Refer to the second photo in this project for mare details The rear window may contain the dete ‘mechanism etnbedded into the glass. W's « wiew dew to be mow careful about cutting into the js because there are wires actually running through the seal. However, these wires in most cies don't run though the ares that you are cutting. To be on the safe side, try to score the seal without cutting ail the wey through, and then tear it by pulling on an endl thot is loose (similar to the second photo inthis pro. ‘ec\), This should help you remove the glass withaue damaging the wires, ‘After the seal has been cut in hal, there should be nothing really holding in the windshield. Ty wiggling ie to see iritsloose. There is a chance that the rubber on the seal may be sticking to the windshield, in which case you ray have to apply sight pressure using your hands (no tools!) on the inside of the windshield. I the seal is significantly stuck on the inside, use 3 plastic putty scraper to separate the saal from the glass or the inside. Don't worry about the glass faling out or sliding—gravity will keep itin its original spot. When the windshield is finaly loose, you can rock it up on its bottom and remove it from the car Depending upon how long your arms are, you might want to have an assistant hep you. Its not heavy, but its not too light either. Make sure that you store your Windshield in a very safe spot where it won't get dam- aged or stepped on. ‘The removal process for the side glass is wey sim- 1 On 911s with the pop-out rear side windows, you can simply unbolt the entire glass, and then worry about the seal without the concem of breaking the glass. On 911s without the pop-out roar side win- dows, the removal processis almost exactly the same as the windshield. Be very careful not to use any tools to pty the window out. For the rear, the process isa made a bittrickier by the addition of the defroster After you cut and remove the inside part of the seal, you should be able to see the elecirical connections that are attached to the glass. Its very important to remove these conne= tions before you remove the glass, as they can bend ‘and break if you don’t. Simply unplug the wires from the alas. There should be four in total, With the plugs: disconnected, you should be able to remove the rear glass just like the front windshield. if by some chance you do break your windshield, replacements are somewhat common, and easy 10 find. Most windshield shops will come and instal 3 new windshield in your ear for about $150 (here in Southern Califomia). Other locations may charge. bit more, but the general price range shouldn't vary 128 much from this figureva __ Ciao © INSTALLING » Ja Depends on whith window you ore instling » Tinwore: Nev ute fr be window > Tip Pred vy, vex oly, nd de’ rh isnot ok Nstmoee wind in your foce ri - OE 1ON: Replece window Misee metsle sbour iy eieating glass into your car is not an easy task. There probably isn’t sche shop out there that won't admit to break- ing atleast one windshield trying to install it. The tick ito have plenty of patience, and to make sure that you don't put any excess pressure or loads on the 28s. However, the process of installation requires that you push slightly on at least part of the glass. As the glass ages, it can become very brittle, and may crack a fot easier than a new windshield Unfortunately, you may end up doing everything right nd sill break your windshield. The procedure for the installation of the front windshield is similar forthe other panes of giass in the ‘ar. The main difference is that the front windshield i> very large, and has an increased tendency to crack because i's much longer. The length of the glass m2/ Actually magnify stresses and forces placed on the Windshield. The side windows and rear glass are less Susceptible to cracking, However, the rear window woe special consideration because of the defroster \wite that is-running through the seal. For the rema} der of this Gee ‘wa'll concentrate mostly on the front windshield, and then give hints and tips on how the other panes are different. The first step in installation is to attach your rub- ber seal to the edges of the glass. I's really not a wise idea to recycle an old seal, as these were probably damaged in the glass removal process, and will not seat properly. Always use 2 new seal, | also recom: mend that you only use OEM German rubber when replacing your seals. I've found that most of the cheaper reproduction seds are of an inferior quality. it’s not worthit to save a couple of bucks, only tohave the seal leak on you st a later date, Before you install the seal on the glass, make sure that you place the windshield on a scratch-free sur face. An old rubber tie with a blanket tossed over i makes an ideal candidate. When you fitthe seal to the Glass, make sure that the orientation of the seal is cor- rect. The groove for the aluminum bezel always faces toward the outside of the windshield. Using a bit of soapy water on the edgesof the windshield may help with the installation of the seal When the windshield is to be installed into the can a strong cordis used to properly pul the edges of the seal inward. The cord must be inserted into the: inner ridge of theseal prior to placing the window on the car, After the seal is properly mounted on the vindahield, thread the cord into the channel groove wi the seal, Refer to the diagram that accompaniesine How pet pane » tools; Sy oc le Don iit 2 ‘Applicable Years: All ® Tob Ses yo ress » Tinwor » Idec to ote eke eae | ! | | ye of the most perplexing tasks to perform on the 911 is the removal of the window glass, whether its the front or rear window, or either of the know what you are doing. However, with a few ‘is ond stepby-siep instiuctions, the process i made much easier. A few of the projects in thie book require remav- ing ard replacing the wincow glass—replacna the Wield seal (Project 80, instalina a new dash pad (f0iee 67), ard replacing the: interior headliner (ect 8). The process of removal can be cuite "ky. 50 (ve dedicated an entire project tit ANI four major pieces of glass on the 911 coupe 28 atachectin 9 similar mariner. The front windshield weal asthe rear and two aide quarter windows are ‘4in pimarly by a rubber sea) that grabs both the Sestand ‘the chassis of the car. It's a very similar sys ‘St 0 the one used on the 386. The 911 cabriolet ‘arga have the same system for mounting the Toutting and securing the rear window. The rear 'S? Window installation le very difficult, and you should probably enlist the help of someone who has done it previously. Cn earlier 211s with rear pop-out windows, the process becomes even easier, 28 the glass and frame are cimply unscrowed from the car The first step in removing the glass isto carofully remove the widow molding from the car. The early cars were equipped with chrome. window molding that actually inserts into the glass seals. On the later cars, this trim was anodized aluminum. In either case, itis very easy to damage and destroy the molding when you ere removing it Forthe windshield, start bytakings meduum-sized serewdriver and siding the little maleing joining clos that are located on the top and bottom to the side. Don't scratch the molding with the screwdriver: Now, carefully gently pry up one part of the molding with: the screwdhiver. Work carefully, and make-sure not to. bbend the metal trim as you are removing is Ifthe trim isbent signficentl, then it will be nearly impossible 10 reinstall when youtry to replace the windshield Gently move around the perimeter of the mold- ing using the screwdriver to pry it up: Never take one ‘end of the molding and pull on it, as this can bend it beyend recovery. Just carefully inch the screwcriver around the molding, being very careful not to bend it Significantly. If you need any encouragement on hav- ing patianes, just keep. in mind that f you damage them, these two places are about $75 each to replace. The rear window and side window pieces are: leven more expensive to replace, so the key word here