Carlex Notifies Customers of Non-Safety Related Quality Issue on DW001529 GTY/GBY Product

Carlex has alerted its customers about a non-safety related quality issue on some Carlite DW001529 GTY/GBY product, which might show an increased rate of cracking during installation.

“The issue is limited to a small percentage of windshields produced by DOT 287 with date codes 2AB, 2AC and 3E,” explains Don Michelotti, Carlex executive vice president.

He says the company has been performing an 8D root-cause analysis (a team-oriented, structured problem solving methodology) to review the issue.

“An 8D root-cause analysis in progress for three weeks has identified that windshields manufactured by a sub-supplier for Carlex may show an increased rate of cracking during installation. Many customers have had no issues and the rate of cracking has been found to be influenced by the various installation techniques used in the field,” Michelotti says.

“These windshields can continue to be installed in the field as there is no safety issue with the product. Although the rate of cracking is very low, it exceeds Carlex’s internal quality standards. Carlex will address the various quality concerns of its customers,” he continued.

Michelotti stressed that the impacted product is safe to install, saying it “was validated with safety testing at the time of manufacture per industry standards and retested by Carlex to confirm that all products meet or exceed all FMVSS and ANSI safety requirements.”

“If you have any questions please contact your Carlex sales representative,” Michelotti adds.

Once the root-cause analysis has been completed and corrective action has been taken by the sub-supplier, Carlex will resume manufacturing the `1529 product at its own plant in Nashville, Tenn., according to Michelotti.

“Limited product will be available from Carlex/Nashville within two to three weeks,” he says.

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3 Responses to Carlex Notifies Customers of Non-Safety Related Quality Issue on DW001529 GTY/GBY Product

  1. It is reassuring a supplier is being Pro Active! Thanks!

  2. Jeff Olive says:

    We have installed the windshields listed above and have the vehicles return two and three times with stress cracks. The stress cracks did not happen during install. The stress cracks appered within one to three weeks after the install. All instlations were performed to factory specks, set properly, and using the same brand of urethane the factory uses. I am glad to see that Carlex is identifying the problem. I urge the glass suppliers to pull the defective product from there stock. I have received DW1529 windshields with the DOT and date codes for the defective product within the last week. The replacement DW1529 was ordered for a warranty job, stress crack.

  3. Joseph Roskoph says:

    The DW1529 is inherently prone to stress cracking in general. The format of the installation as engineered by Ford provides poor spacing of the glass to the body at various points – the thin urethane bead at these points delivers insufficient cushion for the windshield at those specific areas. This is evident by the difficulty in removal by cold knife in a substantial portion of the perimeter. The effect of body flexing and even minimal impact can trigger spontaneous cracking events here.

    We counter this scenario by adding a 1/4 inch Marcy dam across the bottom of the glass, in conjunction with a Marcy 3/16 dam across the top. This upper dam still provides a decent molding profile to the roof while structuring a sufficient urethane bead thickness there and even down the A-pillars. The result: a uniform urethane bead with a precise windshield fit, in conjunction with minimizing the incidence of spontaneous cracking.

    Some of us lived through the nightmares of the Ford Escort replacements. Same theory – inadequate urethane spacing glass-to-body. Can’t get away with it on a windshield and body opening F-150 sized. Let’s wake up Ford.

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