The most likely cause of a total defroster grid failure is a separated
main power clip/tab.
Located on each side of defroster on the vertical
side bars, these critical tabs connect the defroster grid with the
vehicle’s high amperage defroster circuit.
These all important tabs can be knocked off of
the defroster causing total defroster failure. Look for dangling
wires near the sides of the defroster as a sure indication of this
Once this problem has been identified the challenge
becomes reliably reattaching the tabs without damaging the back
glass or the defroster.
How to Reattach Tabs
It is easy to reattach these separated tabs. First pull the metal
tab out of its connector. Inspect the tab carefully, if damaged
then replace it with new tab.
See Uni-Clip Defroster Tabs.
Next sand the base of the tab to bare metal using
the sandpaper included in the kit. Now inspect the area on the defroster
where the tab will be bonded back. This area should be clean and
relatively smooth. It may be necessary to sand this area lightly.
Damaged Defrosters, Tab Repair with lots of missing defroster
If the defroster around the tab was
damaged when the tab came off it is easy to rebuild the damaged
area on the defroster while at the same time re-attaching the
separated defroster tab.
Start by masking off an area around the
damaged bonding site with masking tape making sure some of the
undamaged defroster is inside the masking area. Remember you are
making an electrical connection to the undamaged defroster while
restoring the defroster in the area where the defroster was
It is a good idea to use two layers of
tape. Now mix the 2000 Frost Fighter Tab bonding material and
apply it to the inside of the masked off area. Use one of the
kits mixing pads to squeegee the material smooth. Pull off the
masking tape. Now you will have a nice wet pad on conductive
epoxy that overlaps onto the undamaged defroster surface.
Next, dip the end of the tab into the
adhesive and position it on the bonding material on the
defroster. Remember this adhesive starts to cure quickly (five
minutes). Once the tab is in place the allow 10 to 15 minutes
for the adhesive to start to cure and then use heat for the
final cure. The highly conductive silver filled epoxy cures
quickly and bonds aggressively forming both the electrical and
If the tab is damaged replacement tabs are
Hot tip for faster,
more conductive cure
For the best electrical and structural properties heat the
repair when curing. Use a hair dryer, heat gun or electric heater,
heat lamp or other heat source to keep the bonding area warm during
the repair and cure period. Heat to between 100 and 130F
(37-54C) or warm
to hand for at least thirty minutes for the best results.
The Frost Fighter tab bonding kit is safe for
all defroster tab configurations.