1. Preparation:
* Gather Tools and Materials: You'll need a windshield removal tool (a strong suction cup and/or a specialized cutting wire are recommended), a new windshield (ensure it's the correct one for your year and model), a razor blade or scoring tool, plenty of clean rags, isopropyl alcohol, a sealant (urethane, specifically designed for automotive glass), a sealant applicator gun (if using bulk urethane), and possibly a helper. You might also need a putty knife and plastic trim removal tools.
* Prepare the Vehicle: Park the truck on a level surface. Disconnect the battery's negative terminal. Remove any interior trim pieces (dashboard, A-pillars, etc.) that might interfere with access to the windshield. This often involves removing screws, clips, and possibly some weather stripping. Consult a repair manual for your specific truck model for detailed instructions on removing interior trim.
* Clean the Frame: Thoroughly clean the windshield frame where the new glass will sit. Remove any old sealant, dirt, dust, or debris using the razor blade and rags. Isopropyl alcohol will help remove any remaining residue.
2. Windshield Removal:
* Cut the Old Sealant: Carefully score the old sealant around the perimeter of the windshield using the razor blade or scoring tool. This weakens the bond and makes removal easier.
* Use Removal Tool: Employ the suction cup and/or cutting wire to help separate the windshield from the frame. Work slowly and carefully to avoid shattering the glass. The windshield might be held in place by clips as well, so be mindful of those.
* Remove the Windshield: Once the sealant is sufficiently broken, gently lower the windshield out of the frame.
3. Windshield Installation:
* Prepare the Frame: Clean the frame again, making sure it's perfectly clean and dry. Any remaining debris will compromise the seal.
* Apply the Sealant: Apply a bead of urethane sealant to the frame following the manufacturer's instructions. This is crucial for a proper and watertight seal. Use the applicator gun if you're using bulk urethane. A continuous bead is important.
* Install the New Windshield: Carefully lower the new windshield into the frame, ensuring it's properly seated and aligned. You might need a helper for this.
* Clean Excess Sealant: Remove any excess sealant immediately with a clean rag and isopropyl alcohol.
* Allow to Cure: Allow the sealant to cure completely according to the manufacturer's instructions (this can take several hours or even overnight). Do not drive the truck during this time.
4. Reassembly:
* Reinstall Trim: Once the sealant has cured, carefully reinstall all the interior trim pieces you removed earlier.
Important Considerations:
* Repair Manual: A repair manual specific to your 1984 Chevy pickup is highly recommended. It will provide detailed instructions and diagrams for removing interior trim and other steps.
* Professional Installation: Replacing a windshield is a complex job with the potential for serious injury and damage if not done correctly. Unless you have prior experience with automotive glass replacement, it's strongly recommended to have a professional auto glass shop perform the installation. The cost of professional installation is often less than the cost of repairing potential mistakes made during a DIY attempt.
* Safety: Always wear safety glasses and gloves. Windshields can shatter unexpectedly, causing serious eye injuries.
This guide provides a general overview. The specific steps may vary slightly depending on your truck's model and the type of windshield. Always consult a repair manual for your specific vehicle. Remember, safety first!
