Reusing Windshield

WARNING: This page is about a different car, the 2004 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Before removing the windshield from the body, mark the position of the windshield by affixing tape to the windshield and body panel.

Make a hole through the sealant from the inside of the vehicle using an awl, avoiding the pins.

Fig 1: Identifying Pin
Courtesy of MAZDA MOTORS CORP.
Pass the SST (piano wire), cut to sufficient length, through the hole.
WARNING:
- Using the SST (piano wire) with bare hands can cause injury. Always wear gloves when using the SST (piano wire).
Wind each end of the SST (piano wire) around a bar.

Fig 2: Using Piano Wire To Cut Through Hole
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Use a long sawing action to spread the work over the whole length of the SST (piano wire) to prevent it from breaking due to localized heating.
Fix one end of the SST (piano wire), and while pulling the other end, cut the sealant around the windshield.
NOTE:
- As the upper part of the pin adheres to the sealant, cut it using the SST (piano wire).
Fig 3: Cutting Sealant Around Windshield
Courtesy of MAZDA MOTORS CORP.
Cut the pins out.
Remove the windshield.
Mark the seating positions of the pins and remove the pins from the windshield.
Remove the windshield molding from the windshield.

Fig 4: Identifying Cutting Line On Pin
Courtesy of MAZDA MOTORS CORP.