1. Preparation is Crucial:
* Safety First: Wear safety glasses, gloves, and long sleeves. The glass is sharp and you'll be working with sharp tools.
* Tools You'll Need: You'll need a windshield removal tool kit (usually includes a cutting wire, suction cups, and possibly a small hammer), a razor blade or scoring tool, a large flathead screwdriver, several putty knives, plenty of towels, and possibly a helper. A shop vac can help clean up broken glass.
* Gather Supplies: Have plenty of clean towels ready to absorb water and protect the interior. You might also want masking tape to protect the van's paint.
* Disconnect the Wiper System: Disconnect the wiper arms and motor before you start. This will prevent damage and allows you to have better access to the glass.
* Remove Interior Trim: Remove any interior trim around the windshield that might interfere with the removal process. This typically involves unscrewing plastic pieces and gently prying them loose.
* Locate and Cut the Urethane: The windshield is sealed to the frame with urethane sealant. You need to carefully cut through this sealant to separate the glass from the frame. This is where the special cutting wire is crucial. Use the wire to cut through the entire perimeter of the sealant. Be slow and methodical to avoid damaging the car's frame.
2. Removal Process:
* Score the Seal: Before using the wire, use a razor blade to score the sealant to make it easier to cut through.
* Use the Cutting Wire: This is the most delicate part. Carefully and patiently use the cutting wire to cut through the urethane bead around the entire perimeter of the windshield.
* Suction Cups: Use the suction cups to help lift the glass once you've cut through the majority of the urethane. It will likely be very heavy and awkward.
* Gentle Rocking: Once the glass is loosened, gently rock it back and forth to break the remaining bond.
* Removal: Carefully remove the windshield, ensuring you don't damage the surrounding metal frame. Have a helper to assist in supporting the heavy glass.
3. Cleaning Up:
* Clean the Frame: Thoroughly clean the frame of any remaining urethane and glass fragments.
* Dispose of Glass Safely: Dispose of the broken glass properly, following local regulations.
Important Considerations:
* If you are uncomfortable with any part of this process, DO NOT proceed. The risk of injury is significant.
* Professional Installation is Recommended: Windshield replacement is a specialized job that requires experience and the right tools. It's much safer and likely cheaper in the long run to have a professional auto glass shop handle this. They have the proper tools and training to do the job quickly and safely.
This is a generalized guide; variations may apply to your specific vehicle. Always consult a repair manual specific to your 1993 Dodge Caravan for detailed instructions and diagrams. Again, professional installation is strongly recommended.
