Dodge Journey: Grid, defogger, rear



WARNING: Materials contained in the Repair Kit (Part Number 04549275) may cause skin or eye irritation. The kit contains epoxy resin and amine type hardener, which are harmful if swallowed. Avoid contact with the skin and eyes. For skin contact, wash the affected areas with soap and water. For contact with the eyes, flush with plenty of water. Do not take internally. If taken internally, induce vomiting and call a physician immediately. Use with adequate ventilation. Do not use near fire or flame. Contains flammable solvents. Keep out of the reach of children. Failure to follow these instructions may result in serious or fatal injury.

Repair of the rear glass heating grid lines, bus bars, terminals or pigtail wires can be accomplished using the Mopar Rear Window Defogger Repair Kit (Part Number 04549275) or equivalent.

Heated Glass
Fig. 4: Grid Line Repair - Typical

1. Mask the repair area with masking tape (3) so that the conductive epoxy can be applied neatly. Extend the epoxy application onto the grid line (2) or the bus bar on each side of the break (1).

2. Follow the instructions in the repair kit for preparing the damaged area.

3. Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the packaging. Fold the package in half and cut the center corner to dispense the epoxy.

4. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19 millimeters (0.75 inch).

5. For a terminal or pigtail wire replacement, mask the adjacent areas so the epoxy can be extended onto the adjacent grid line as well as the bus bar. Apply a thin layer of epoxy to the area where the terminal or pigtail wire was fastened and onto the adjacent grid line.

6. Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place it in the proper location on the bus bar. To prevent the terminal or pigtail wire from moving while the epoxy is curing, it must be wedged or clamped.

7. Carefully remove the masking tape or template.

CAUTION: Do not allow the glass surface to exceed 204º C (400º F) when using a heat gun, or the glass may fracture.

8. Allow the epoxy to cure 24 hours at room temperature or carefully use a heat gun for 15 minutes. When using a heat gun, hold it approximately 25.4 centimeters (10 inches) from the repair and do not allow the glass surface to exceed 204º C (400º F).

9. After the conductive epoxy is properly cured, remove the wedge or clamp from the terminal or pigtail wire.

10. Connect the wire harness leads to the grid terminals or pigtail wires and verify EBL operation.

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