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Autopapyrus · Toyota Toyoace (U300/U400)
https://autopapyrus.com/guides/toyota/toyoace/windshield-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Toyota Toyoace (U300/U400): Windshield Replacement

The windshield on this generation of Toyoace may be bonded with polyurethane or installed in a rubber seal with a decorative molding. The exact procedure for this model is not documented in publicly available service materials, so below is a general approach that works for both versions. First, use the old glass to determine which mounting type you have.

Difficulty: Medium Time: 2-3 hours (plus adhesive cure time per the manufacturer's instructions) Steps: 14 Tools: Windshield cutting knife or cut-out wire for removing sealant, glass suction cups, flat screwdriver or trim clip remover, wrenches and sockets for the wiper arms, masking tape, degreaser, glass and body primer, cartridge of polyurethane adhesive sealant, cartridge gun, gloves, safety glasses, a helper

Part

  • 🔩 Windshield for Toyoace U300/U400 (flat-glass cab, no factory heated-wire grid) and the perimeter molding or sealing strip, if fitted. Also: bonding kit (primer, activator, one-component polyurethane adhesive). The exact part number for this model's windshield is not confirmed in publicly available sources, so only the part name is given. When ordering, check the cab's appearance and mounting method against your vehicle

Step by step

14 steps
  1. Determine the mounting type: if you see a thin black bead of sealant around the perimeter, the glass is bonded; if you see a rubber profile with a chrome or black trim insert, the glass is seated in a seal.
  2. Cover the dashboard, seats and hood with cloth or plastic sheeting to protect them from glass fragments and tools. Put on gloves and safety glasses.
  3. Remove the wiper arms (mark their position with tape on the glass), the cowl cover or the plastic grille below the windshield if it is in the way, the interior mirror and the side pillar trim panels.
  4. Disconnect everything attached to the glass: sensors, antenna, stickers, if present.
  5. For bonded glass: run the wire or knife through the sealant from the inside out around the entire perimeter, carefully, so you don't cut into the body or damage the paint. For glass in a seal: soften and fold back the inner rubber lip with a screwdriver, then push the glass out from the inside, starting at a corner, with a helper outside.
  6. Lift the glass off with suction cups and set it aside in a safe place.
  7. Bonded glass: trim off the remains of the old sealant, leaving a thin layer of 1-2 mm around the perimeter. This is the base for the new adhesive, so you don't need to clean down to bare metal. If there is rust or paint damage, clean it, treat it with a rust converter and apply primer.
  8. Glass in a seal: inspect the rubber and replace it if it is cracked, hardened or has lost its elasticity. Clean the mounting flange of dirt and corrosion.
  9. Degrease the flange and, for bonding, the edge of the new glass around its perimeter. Apply primer to the glass and the body strictly according to the kit instructions and allow the specified drying time.
  10. Bonding: apply a triangular-profile bead of adhesive around the perimeter of the glass or the flange without gaps, keeping the height specified in the instructions. Cut the cartridge nozzle to the required profile.
  11. Position the glass with suction cups evenly on the marks or gaps on both sides and press it down smoothly. For glass in a seal: insert the glass into the profile, feed a pull cord into it, and pull the cord out from the inside, drawing the rubber lip over the flange until the glass seats in place. Then install the molding.
  12. Secure the bonded glass with masking tape so it doesn't slide. Do not slam the doors, and keep the windows slightly open for the time stated on the adhesive packaging.
  13. Check for leaks by spraying with a hose without heavy pressure. If there are leaks, add sealant at the leak point.
  14. Reinstall the wipers, mirror, trim panels and sensors. Do not wash the vehicle or drive on rough roads until the adhesive has fully cured.

Common mistakes and warnings

  • A bonded windshield is part of the cab's structural strength and affects safety in a crash and the operation of the airbags, if fitted. Poor bonding or failing to observe the adhesive cure time is dangerous. If you have no experience with auto glass, have a repair shop do the work. If you replace it yourself, always work with a helper, since the glass is heavy and its edge is sharp.