Mercedes-Benz Ponton
Windshield Removal and Replacement

by Gary L. Moy (removal) and Ray Ilich (installation)


I thought that I would relate my experience with glass removal. Note: This is for only rubber gasketed glass. Do not try this with glued on or urethane kit windshields or glass.

I learned this method from wrecking yards and have tried it on three cars that I parted out and two that I haven't. I have never broken any glass with these methods.

  1. Remove all glass trim first. (Inside wood, and mirror. It is not necessary to remove the dash.)
  2. Get Stanley knife or any utility knife with new blades. (put on gloves for safety)
  3. Slide blade along glass and into rubber seal. (Use one hand to steady another and do not cut into metal frame)
  4. Cut rubber gasket by sliding blade along glass. (I found it helpful to cut both the outside and the inside. RI)
  5. When all outside rubber is cut approximately flush with glass gently have helper push from the inside. If glass does not come up toward you, insert blade and cut rubber gasket 90 degrees to glass between metal and glass. (Absolutely NO prying on glass!!!!)
  6. Again, have helper push from the inside of car and glass should come free.  This of course destroys the gasket and a new one must be fitted before glass installation.

An alternative method, although with more risk is after trim is off is to:

  1. Loosen rubber from body using a flat piece of wood.
  2. Start in the upper left hand corner of the windshield, gradually pushing windshield or glass out with rubber.  You may need to have your helper steady the glass as it comes out. (Saves gasket if you are careful)

There are another methods but these two I believe are among the safer ones.  Patience is the key to both of the methods.

Hope this helps,

Gary L. Moy / 1988 Mercedes-Benz 190E / 98,000 miles / Seattle, Washington metropolitan area 


Tools Required: 8' window shade cord; 1/2 oz. Liquid detergent, windshield gasket sealer (butyl), talcum powder, towel, mineral spirits (or kerosene), masking tape

  1. Optional. Build a cradle on which to place the new windshield. The cradle is basically two short sawhorses with carpet secured to the top 2x4s. The carpet guards against scratches. Also remove all trace of the old windshield gasket from the windshield frame of the automobile. Now is the time to correct any rust which might be present.
  2. Place the new windshield concave side up on the cradle, or on a towel-covered Kitchen counter. You might assume the towel protects the glass, but it actually protects the counter from the gooey adhesive in step 5.
  3. Measure and mark (with a crayon) the bottom center of the windshield.
  4. Place the new windshield gasket on the windshield. Match up the vulcanized join on the bottom center of the gasket with the crayon mark. Slip the gasket over the windshield working from the bottom center to the bottom corner and then from the bottom center to the bottom other corner and continue working around until the entire gasket is in place. An extra set of hands to hold the gasket in place is a great idea. Upon completion you may want to take a break, sometimes it's a good workout.
  5. Gently peel back the forward edge of the gasket and sparingly apply butyl windshield gasket sealer between the gasket and the forward edge of the windshield. Do not apply cement to top edge. This is a gooey, messy job. Apply cement sparingly, but be prepared to clean cement from glass, counter, ceiling, floor and fingers.
  6. In a small fingerbowl, mix approx. 1/2 oz liquid dish soap and 1/2 oz. water.
  7. Repeatedly dip your index finger and thumb (or a small brush for the fastidious) into the above mixture and liberally wet the protruding edge of the windshield surround.
  8. Insert the protruding edge of the windshield surround into the windshield gasket groove. Push it into the groove all the way around the windshield. Take a break, you deserve it.
  9. Cut in half the 8' window shade cord (approx 1/16" diameter nylon cord).
  10. Insert the pieces into the groove where the metal window frame will reside.  Tape the ends of the cord to the inside of the glass to help it hold position.
  11. Generously apply talcum power into the groove and trailing edges of the gasket. I used Old Spice Talcum Power, it acts as a lubricant, and as a bonus, temporarily gives the car's interior a gentlemanly aroma!
  12. With an assistant, place the windshield assembly in proper position on the outside of the car. It may help to place the bottom edge first, then tilt back the top edge.
  13. Have the assistant press firmly on the windshield from the outside as you pull the cord out of the groove, pulling the gasket into the interior of the car. I worked about 6 inches on the top then 6 inches on the bottom, working around to the side, alternating top and bottom until one side was inserted. Then switch to the other remaining cord working top and bottom, working around until the installation is complete.
  14. Don't be afraid to abort the installation at an early stage, (prior to completing one side) if you feel that the windshield is not properly positioned. However if you need to restart, go back to step ten, reinserting the cord into the groove
  15. Again clean the windshield using a window cleaner. Remove any errant residual windshield cement with mineral spirits or kerosene.
  16. Reinstall the left and right wood window surrounds, and the rear view mirror.

- Good Luck with your installation!  I hope it goes as well as mine.

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