How to Install a Windshield on a Suzuki Samurai

by Katherine Harvey
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Introduced in 1984, the Suzuki Samurai is a revamped version of the Suzuki Jimny, a popular SUV that has been in constant production since 1968. Like any vehicle with serious off-road capabilities, the Samurai is prone to windshield damage. Cracks or breaks in your Samurai's windshield are not a problem you can put off addressing. Besides the fine the police can levy against you for your broken windshield, your Samurai just isn't as safe in the event of a collision. While it is best to seek professional help for this particular repair task due to its difficulty, it can be done at home as a do-it-yourself project.

Step 1

Remove the windshield wipers. Pop the cap off at the base of the wipers with a flat head screwdriver, then remove the bolt underneath with a socket. Once the bolt is removed, the windshield wiper will lift off your Samurai.

Step 2

Remove the trim from around the windshield of your Samurai. While this can be accomplished with a windshield trim tool, your flat head screw driver will work just as well. Just work the edge of your tool under the trim and lift up, disengaging the clips that hold the trim to your windshield. Try not to break the clips underneath. You will need them to replace the trim later.

Step 3

Cut through the band of urethane adhesive holding the windshield in. The band will run around the edges of your windshield, and needs to be cut away as evenly and thoroughly as possible.

Step 4

Loosen the windshield in its frame. Place the edge of a crowbar under one of the bottom corners of the windshield and force it up. Once the corner is loose, continue loosening around the entire frame. Be extremely careful because it is very easy to shatter your damaged windshield at this point in the process.

Step 5

Lift the windshield by the edges and remove it from your Samurai. You should get help from a friend to do this because the windshield is both surprisingly heavy and fragile.

Step 6

Wash the frame in which the windshield sits with a clean, wet cloth, then dry it completely.

Step 7

Paint on a flat, even coat of urethane primer over the windshield frame. The primer is what causes the adhesive to bond to the windshield, so it's vital that you ensure that it covers the area where you lay the adhesive down.

Step 8

Use a caulking gun to set down a new band of urethane adhesive around the frame.

Step 9

Set the new windshield into place. You'll want to have your friend help again. Make sure the windshield lays flat in its frame, and is set in right side up.

Step 10

Replace the trim and the windshield wipers by following steps one and two in reverse.

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