Originally Posted by jchosler
Thank you JWA!!
I did by the new butyl material the other day and plan on replacing that on all the windows starting as early as today i think.
Move slowly, don't force things or have your local auto glass service on speed dial.
When removing existing windows loosen and remove all nuts EXCEPT two at the top of the window. GENTLY pry the window assembly away from the body using some sort of NOT sharp tool. Looking at the plastic separating ring between the glass and body there should be small recesses allowing inserting of the pry tool to begin moving it outwards.
As the window assembly comes free of the body along the bottom and sides have a helper on the outside hold the glass mostly in place, their fingers between the window and the body. Remove the top two nuts and the window should be free.
Place it on a cushioned work bench or surface and clean all old butyl off the body and what you can see still on the glass assembly. Some of those assemblies have the plastic separator ring permanently attached to the glass, others that part has butyl between it and the glass. If permanently attached just clean the single surface that fits against the body---if it does separate clean both sides as well as the glass and body too.
Once every bit of butyl is removed time to apply the new butyl. There is a "track" in the plastic separator ring---follow that carefully. (If the ring separates from the glass same procedure but do the glass side first then place in one the glass, place the attaching bolts through the glass as though its ready to install back on the body.)
Carefully align the bolts with the body holes and place the glass on the body, your helper having moved inside and placing the nuts on the bolts. GENTLY push the wonder against the body and its as stuck as it needs to be.
Once inside use a nut driver to tighten the nuts just a bit at a time in a circular manner---this is where so many make mistakes. You're squeezing the butyl strips so keep that in mind. You'll feel it squeezing out, can probably see it too. Once the bolts feel snug and you can't really tighten them any further you're done.
I do suggest doing this start-to-finish one at a time---if there are any issues the van isn't completely open to the weather.
I've also sent a PM with my phone number in case you need a bit more immediate response.