Chevrolet 1977 light duty truck, Service Manual

Page: 170 / 861

Fig. 2 D -1 0 1 -W in d sh ie ld Glass
1. Before rem oving the windshield, mark the
location o f the break on the w indshield ru b b e r channel
and the body. Protect the p a in t finish inside o f the cab.
M ask a ro u n d the win dshield o p en in g and outside, lay a
suitable covering across the hood and fenders.
N O T E : The windshield glass ru b b e r weatherstrip is
one piece. The glass is held in a channel within the
weatherstrip.
2. D o not try to remove reveal moldings while
win dshield is in body opening. Remove reveal molding
fro m custom w e a th e r s tr ip r e te n tio n groove a fte r
win dshield is removed fro m body opening.
3. To free windshield ru b b e r channel o f w e a th e r­
strip loosen the lip o f the w indshield w eatherstrip from
the pinchweld flange along the top and at the sides by
a pplying firm, controlled pressure to the edge o f the
glass. At the sam e time assist the lip o f the ru b b e r
w e a th e rstrip channel over the pinchweld flange with a
flat bladed tool.
C hecking W indshield Opening
D ue to the expanse an d contour o f the windshield it
is im perative in the event o f a stress crack that the
win dshield opening be thoroughly checked before
installing a replacem ent w indshield. The replacem ent
glass is used as a template.
1. Check for the following conditions at the
previously m arked point o f fracture.
a. C hip p ed edges on glass.
b. Irregularities in body opening.
c. Irregularities in ru b b e r channel weatherstrip.
2. Remove all sealer from flange and body around
w indshield opening.
3. Check flange area for solder, weld high spots, or
h ardened spot-weld sealer. Remove all high spots.
4. Check windshield glass to opening, by support­
ing glass with six spacers contained in packet J-22577, as
shown in figure 2D-102.
C A U TIO N :
Do not strike glass against body
metal. Chipped edges on the glass can lead to
fu tu r e breaks.
N OTE: It is necessary to m odify the spacers by
cutting off 3 / 1 6 " from the back o f the spacer with
a knife, as shown in figure 2D-102.
With the windshield supported and centered in
its opening, check the relationship o f the glass to the
body opening flange around the entire perim eter o f the
glass.
6. Check the relationship o f glass to opening as
follows:
a. Inside edge o f glass to body flange.
b. Outer edge o f glass to parallel body metal.
7. M ark areas o f body metal or flange to be
reform ed, remove glass and correct as necessary.
8. Recheck windshield in its opening and if
satisfactory proceed as follows:
Installation
1. Apply sealer to weatherstrip and install on glass.
2. Install a cord a round periphery o f weatherstrip,
leaving a loop at the top and the loose ends at the
bottom. See figure 2D-103.
3. Place protective covering over plenum grille,
front fenders and hood.
4. Place windshield and w eatherstrip assembly in
opening. With one technician lightly pushing in on
windshield, a n o th er technician within the cab should pull
on the cord as follows:
a. Pull on loose ends until each is within 2" of
its respective upper corner.
b. Pull on loop until cord is within 2" o f the
u pper corners.
C H E C K I N G BLOCKS