85 Windshield seal?

I can hear wind noise at speeds above 40mph comming from the front top portion of the windshield of my 85 carrera. I replaced all 3 seals on the sun roof and they seem to be in correctly.I would like to know the entire step by step on how to replace the seal,trim and sealant if needed.Please help!!

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Mully 911

Hey Mully,

You emailed me, I emailed you back. Here it is for the rest!

Be very VERY careful. I was told the glass tends to become brittle with age.

Disclaimer - Because you are following my directions, does not mean that you can break your windshield and blame me! You touched it, you broke it, your fault!

I spoke with Wayne at Pelicanparts. He faxed me some directions. I have included and modified them as outlined below.

I took out the aluminum trim very slowly and meticulously; I did not want to bend the aluminum trim.

Then I was able to free the rubber from the body, without putting any pressure on the glass yet. You know how rubber and metal are after they have been in contact for so long. I found the top of my windshield popped right out (forward of the car), because my rubber trim was so old and hard.
I pulled the windshield forward from the top, made sure all the rubber was free, disconnected my antenna (antenna is in the windshield) and was then able to lift the whole thing out and set it on its bottom, and had two pieces holding the top so it stands upright within it's old rubber.
I then got a new rubber gasket $35.00 (cheap enough). Made sure it would fit on the windshield. It seemed a little loose. I proceeded anyway.
Took the new rubber off the windshield. Then carefully placed the glass on a thick carpet again with the edge on the carpet (NOT LAYING DOWN, I thought this might break the windshield).
While holding the windshield up I molded each half of the aluminum trim around the windshield, directly on the edge of the glass. Meaning the pointed end which was in the rubber now rests on the glass edge itself.
If you were careful when you took out the aluminum, you should see the aluminum goes right around the edge of the glass. After I installed the shield, I found this to be key to a great OEM fit.
After molding the two halves of aluminum, then I placed the rubber on the windshield. Then I placed the aluminum trim in the rubber using some Dove soap and water.
Now the rubber and aluminum are on the glass and fit well. I then placed the windshield on the car so it rests on the area where it goes in.
Hopefully, you do not have any silicon, or scratches on the paint. The silicon will cause leaks, the scratches on the paint will rust after some time and makes it expensive later on.
I had scratched the paint when I removed the rubber from the framing. I sanded the scratched area, primed it, and painted it. This was inside the windshield frame, so making it pretty was not a concern.
I then got some 5/16 (maybe it was 1/4")-inch Nylon rope, and placed it all around the rubber slot. I made the slot and the car-frame all soapy. You will notice the car frame goes inside this slot of the windshield rubber gasket. I was able to make the bottom car frame go inside the bottom windshield rubber gasket. Took some time to make sure it was in. I then soaped it all up again. I tried to push the glass rubber seal in place while pulling the rope around the bottom. I pulled the rope in a hard tugging fashion almost like jerking the rope. Then I did the left and right sides and finishing at the top of the rubber gasket. I think Pelican Parts says to start at the top and finish at the bottom. It seemed more logical to start at the bottom and finish at the top, as this was the way I took the windshield out, not to mention my integrated antenna wire.
I took quite a bit of time jerking on the rope all the way around the windshield frame. I did not want to go through this a fourth (or fifth?) time.
I tried this four different times until I got it right. Two times I tried to put the aluminum frame on last, instead of before placing the windshield in. The third time I was using the wrong type of rope ( I used twine) it broke a couple of times while pulling on it. Then I got the Nylon and a bar of Dove Soap.
Good luck. Email me if you have more questions.

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Nick Hromyak
'85 Carrera 7 & 9 Fuchs
Havin' Fun in Sacramento

[This message has been edited by nhromyak@yahoo.com (edited 05-14-2001).]