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July/August  2003

The Cutting Edge
    new car installations

2004 Mitsubishi Endeavor 
by Eric Bradley and Phil Ochs

2004 Endeavor


After completing the pre-installation inspection, protect the interior of the vehicle, seats and dash area and remove the rearview mirror. Next, protect the exterior of the vehicle around the fenders and hood using protective tape or silicone hose. Remove the wipers by removing the plastic nut covers and releasing the 13-mm nuts. The driver’s side has one set and the passenger side has two sets to be removed. Next, with the hood open, remove the bulb seal across the front edge of the cowl. Then remove the eight cowl plugs. Now, pull the cowl away from the windshield toward the engine and release the tabs that fit under the glass.

It is recommended to cut the windshield out from the inside of the vehicle. Start by removing the interior “A” pillar mouldings that are held in place by spring clips and are removed easily. Then, using whichever power tool you select, cut the adhesive, using caution not to scratch the pinchweld area. (Note: The windshield sits deep within the pinchweld and exposes the vertical portion of the pinchweld. This area could be damaged easily with the cold knife. We recommend using the full cut-out method.) Using a sharp chisel or utility knife, remove the adhesive, leaving a thin skin of well-bonded urethane on the pinchweld. 

Prime the pinchweld according to your adhesive manufacturer’s specifications. Concentrate on any areas of the paint that may have been scratched or damaged during the removal process. The freshly cut urethane bed provides the best bonding surface. Allow proper time for the primers to cure. Clean and prime the windshield according to your adhesive manufacturer’s recommendations. Apply the new mouldings. (It is recommended to have new mouldings available for this job.).

Dry-set the windshield into the opening, being sure to adjust for proper alignment. Remove the windshield and set it on a cradle with the inboard lite in the upright position. Use a properly cut “V” notch tip to duplicate the original bead size. Apply adhesive to the glass duplicating the original size and location. Set the windshield into the opening using your dry-set marks, being careful not to slide the windshield once the adhesive makes contact with the pinchweld. Two people may be necessary for the installation of this windshield since the bottom of the glass protrudes down and past the metal portion of the dash area. There is no area for attaching setting blocks. Once in place, tape the top of the glass until the adhesive will hold the glass in place.

Replace the cowl panel into position by sliding the tabs under the glass with the top edge of the cowl over the glass. Replace the bulb seal to its location along the front edge of the cowl, return the wipers to their proper position and test for proper travel when done. Test the windshield for leaks and then clean the exterior of the glass. Clean and prep the vehicle. 

Always wear eye, hand and wrist protection while working. Inform the vehicle owner of the cure time and any other additional precautions before installation. Always return the vehicle to manufacturer’s specifications. Protect all interior and exterior portions of vehicle.

Eric Bradley is the service center manager for Auto Glass Specialists Inc. in Monroe, Mich., and Phil Ochs is a technical trainer for the Performance Achievement Group in Madison, Wis.


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