I just found tonight a 91 d-250 diesel, similar to mine in the bone yard this afternoon. Gonna go down here in a little bit and grab the dash, heater controls, pretty much everything associated with the ventilation system, and the condenser...only thing I'm not gonna have yet is the a/c compressor...anyhoo, my question is what is the best way to remove the windshield and put it back on? Prolly gonna start tackling this tomorrow, and it sure looks like windshield has to come out to do this...my dash has been fubar since I've had the truck, finally found a solid one and gonna go ahead and put a/c on while I'm at it...anyway, thanks for the help here...

Brian

 

You might as well plan on replacing it. It is very difficult to remove without cracking. Use a booger hook and go all the way around the seal inside and out. Good luck and be patient!

 

Just had mine replaced and I watched the guy do it. First he removed the rubber rope that is squeezed into a grove on the outside face. this then allowed him to use a double ended plastic knife to lossen the rubber that is pretty well vulcanized to the glass. Then he attempted to gently pry the glass out of its gruve. This diddn't work to well quickley so he put his feet against the inside of the glass and pushed. The glass broke but it was broken any way to begin with. Removing it in one piece is going to take several hours of gentle prying with a plastic knife. WD 40 or silicone spray is very helpfull and an extra pair of hands would be a bonus. It looks like 50- 50 as to getting it out without shattering it. Puting it back in is is the same as taing it out only in reverse. He used the Heel of his hand to gently bounce it back into its gruve working from the uper left cornor. The botom is easy as it will seat when you install the glass in its place. The top cornors are really tough. once they are atleast inside the rubber lip then you work onthe upper middle and the sides. Suction cups with handles are almost a necessity.if you are doing this by yourself. If you get it installed then you need either a special tool to force the sealing rope into its gruve. The cost to do it new by an expert is $300.00

 

Some company's/guys still use the butyl calking and others use the urethane foam. If you use the foam the rubber is in for the long haul and will need to be entirely replaced if you break another windshield, which, is way some still use the butyl calking. It often leaks at the corners though and I am still struggling with mine to keep it from leaking.
Maybe you could use a heat gun to warm things up as you try to remove it....yes/no???

bob....