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Windshield remove/replace
I’ve seen a lot of info over the years about windshield removal/replacement but none that I can recall or find on the larger XL II windshields that go essentially to the roof line. A really big piece of glass with compound curves and vinyl blackout on the upper third or so. In my 2001, the situation is complicated by cabinets all across the front of the bus that leave no access to the top of the glass on the inside so when trying to remove the glass, there is no way to push gently from the inside at the top to get things started. Have taken one out before but did so because it was broken and it broke further getting it out. Have all kinds of big suction cups for lifting/pulling and plastic tools for manipulation of the gasket. Generous use of soapy water, lots of help, warmed the rubber gasket and all that. Installation not much of a chore. Used old gasket. No leaks.
Now have a situation where I need to get the curb side glass out in one unbroken piece and then replace the same piece of glass. Don’t ask. Long story. New glass is about $900 so I’d rather not pop for that if possible.
Does anyone have any experience with getting these huge XL II windshields out in one intact piece? Obviously, just pulling and manipulating the gasket was less than successful. Have talked to Prevost and Marathon and both wished me luck but had no tricks to offer. Can’t find anyone within a thousand miles with any experience/ambition to offer. Am continuing to search diligently for a magic wand.
Mike
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5 Replies
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Did you pull out the lock strip?
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Yes.
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Cabinets at the top is not an issue, all the action starts and mostly takes place at the bottom, specifically the bottom outboard corner is where it pops loose first.
Read my post on replacing refrigerator, it has detailed instructions with hints on pulling this windshield.
/threaddetails.asp?Category=Diagnostic+and+Repair+Nuggets&ThreadID=11655
Things that help are if it is warm it will help a lot, it did it on an 80 degree day in Phoenix, use lotttttssss of dish soap and distilled water, bit by bit, pick out all the dirt grime, gunk out of the channel as you do it, a good pressure washer blasting before starting might be helpful.
Where are you? You say within 1000 miles, but from where?
Call me at 469-207-1362 if you would like.
2000 Featherlite H3-45
2024 Jeep Grand Cherokee
Leesburg, FL -
Will close the loop.
Magic appeared in the form of Dave Lee. In his post he references his experience with the large XL II removal in one piece. And then I did correspond with him directly to calm my nerves. He is the man.
Key for me was to begin at the bottom as Dave suggested. I used a portapower gently on a chunk of 4×4 to keep pressure on the inside. Top start as recommended by Prevost impossible, of course. Only caveat is that when working on the bottom of the rubber gasket (which takes a while), once things begin, gravity takes over. Large, strong grandson very helpful at that point but happens quickly so be ready.
Thank you Dave Lee. Mike
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David has an amazing skill set and is always ready to help.
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