Replacing the window glass in the front door is a very simple repair. Using junkyard glass and doing it yourself can save a significant amount of money. Typical junkyard cost is $75 for the front glass, vs $375 for a new window put in by a glass repair company.
- Latex gloves when working with broken glass
- Torx drivers - for removing door panel
- Pin - to pop out plastic pin on end of door panel
- Paper towels
- 2 new green window rollers
- Window glass
Gloves are great. I got some cuts on my palms and wrists from the little shards that were all over the place, so I put on two layers of latex gloves. No more cuts.
In addition to your window, you will need two new green rollers and some grease.
Nothing here takes a great amount of force. If you're forcing something, you're doing it wrong.
- Remove screws from door panel. There are six total - 1 behind the door handle, two behind the door pull, three at the very bottom of the door.
- Remove the plastic retainer above the door latch. With some skill and luck you can pull out the center pin with a needle in order to reuse it. Otherwise it breaks and you get to buy an overpriced replacement from the dealer.
- Pull off the door panel with a slight counterclockwise twist to get it over the lock and out from under the under the sail.
- Remove the outer foam from the door.
- Remove the inner foam from the door.
- Remove styrofoam chunk from right side of door (not the pieces in the bottom of the door, just the one covering the hole on the right).
- Pry the pins out of the green rollers to remove the old metal tray from the scissor lift.
- Clean broken glass out of door. A vacuum will get some of it, the rest can be brushed out through the drain holes in the bottom of the door.
- If you're working with a used window, clean the old grease and dust out of the channels before putting the window in the door.
- Slide new window into door from above and from outside of door.
- To get the metal tray at the bottom of the window through the weather stripping you have to pry the weather stripping apart with your finger. The tray is sharp and will cut the weather stripping if you aren't careful here.
- There is a sweet spot where the window will slide easily down into the door. It is about one fifth or one quarter of the distance from the back to the front of the window frame, and the window should go in at about a forty-five degree angle. Do not force the window, or move it side to side. If you have it positioned and angled properly, it takes very little force. Forcing it can break the window.
- As the window starts sliding into the frame, hold onto the bottom of the window so that it doesn't drop into the door and break.
- Position the window in the tracks and make sure that the weather stripping is correctly positioned.
- Slide the window up and down to make sure it is properly seated in the tracks.
- Grease the track and put your new green rollers in there.
- Use the window regulator to set the scissor lift at a height that you can reach behind the window and press it into the rollers with the heel of your hand.
- Pop the scissor lift into the rollers until you get to the first click.
- Move the window up and down a few inches to make sure everything is operating smoothly.
- Press the scissor lift into the green rollers until you get a second harder, louder click.
- Put both pieces of foam back on the door.
- Roll the door panel back into position, clockwise.
- Position the door panel so that the plastic rivet things line up with their holes.
- Press the door panel in place.
- Put door handle in position and test it.
- Put all of your screws back into place.