Thursday, November 21, 2013

How replace auto door glass on a 1997 Pontiac Grand Am

The right rear passenger door glass on a 1997 Pontiac Grand Am was shattered with a beer can  by a vandal late one recent night. I repaired it with glass from an auto scrap yard for $25.

1) Remove two Philips screws in the door pull.

Removing the two door pull screws

2) Remove the  hand crank. Separate with a prybar to create a gap so that the a metal retaining clip can be removed. Use a hooked tool to pull the clip out. I used a dental pick.
3) Pry off the red door reflector and remove the Philips screw beneath it.
4) Unsnap the four panel fasteners at the bottom of the door. These are wire on this car.
5) Carefully unsnap the plastic molded piece that covers the handle and the lock lever and pull it to the left.
Turn it so that it slips over the door handle.

Slip the molded piece over the door handle
6) From the outside of the door lift up the top of the big inner panel, by prying it upward with a screwdriver.
There are three downward pointing plastic holders on the panel,  that mount in rectangular cut-outs in the door.
7) Remove the entire inner panel by pulling upward.

Here is a view of the inner door panel when removed

8) Remove the metal door-pull bracket (4 Philips screws)
9) Remove the clear plastic adhesive-backed sheet.
10) Remove the horizontal inner lower window seal.
11) Pull the inner side window seal outward and remove it from the door jamb up to where it heads back down.

Prying out the window guide seal

12) Remove two Philips screws on the inside pillar of the window jamb. Remove the plastic trim piece. Be careful, it’s plastic.
13) Loosen the plastic glass holders ( they were riveted to the window glass) from the under bar with a 10mm socket and ratchet.

Go to scrapyard and remove glass from a junked car. I paid $25 for the glass.

1) Feed the replacement glass through the upper door, seating it in the outer rubber guide. Go to the other side and line the plastic pieces on the bottom with under rail hard ware.  Use the crank if needed to position it.  Tighten with 10mm socket.
2) Install the inner trim piece with the two Philips screws.
3) Re-seat the rubber upper and side window seal in its slot.
4) Test the window operation by temporarily reinserting the crank. If Ok continue.
5) Re-install the plastic sheeting .You may need to use a bit of silicone to hold it in place.
6) Re-install the door pull bracket with the four Philips screws.
7) Re-install the big inner door cover. Push it in place from the top, seating the three upper clips. Then re-seat the remaining panel fasteners.
8) Install the screw behind the door reflector.
9) Install the reflector.
10) Install the window crank.  Put the clip partially in place first, then seat the crank and lock the clip in place with a dental pick or right angle tool.
11) Install the two door pull screws.

Here is a video of this job:


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