I'm a bit late on this but I'll add my tuppence worth anyway as I've had my front screen in and out six times and the rear four. The removal and re-fit process was always carried out by windscreen "specialists"
The first time was to get the screen rust done under warranty - so done at an approved bodyshop. They made a right pigs ear of the front screen (which was a new one as they damaged the old one taking it out - quite common apparantly as the older glass gets the more brittle it becomes) and it had to be removed and re-fitted. The front screen then started to de-laminate after a year or so, so it's back to the bodyshop for a replacement under warranty.
The rust then came back because when they they take the old screen out they use a Stanley type knife which cuts into the paint in the recess. Yet again it's back to the approved bodyshop and both screens out again (this time they broke the rear screen). The front screen had to come out again as it wasn't fitted correctly. Then the rear screen exploded one day about six months after it was fitted when I was getting in the car. I think it was because they had fitted the screen for the 94 model which is different but only sussed this out later. So out again and in with another one, which wasn't fitted properly but by this time I was concerned about the damage they were doing to my car so decided to live with it.
The screen rust re-appeared two or three years later - well it would do when Jack the Ripper is hacking at it without a care in the world wouldn't it? So back into a different bodyshop and out with both screens. The bodyshop called me into to discuss the car once the screens were out and you could clearly see two knife runs in the paint all around the window recesses where the screens had been removed before. The rust wasn't too bad but if left untreated would have quickly developed, so bodyshop bill promptly doubled to cover the additional work. The screens were re-fitted but not properly positioned, however, although the bodyshop offered to take it back in and get them re-fitted I decided that I would rather have a rust free car with incorrectly positioned screens than a car with correctly positioned screens and hidden rust waiting to burst out at some future date.
I don't really know what makes the fitting of these screens so difficult. I know that they are bonded to the inner rubber seal as opposed to the screen surround in modern cars but surely that's not the reason?
Anyway, I now consider myself something of an expert on how fitters can in-correctly fit both front and rear screens, so here's a list of the things that they can get wrong:
- Glass fitted too high or low within the aperture, i.e. too close to the roof or scuttle panel
- Glass not centred, i.e. too far to the left or right
- Glass fitted squint, i.e. right side higher than left or vice versa
- Glass fitted too far into the aperture, resulting in outer rubber not sitting in the edge channel properly and coming loose
- Glass not sitting far enough into the aperture, resulting in the rubber not sitting against the bodywork properly
- Any two or more of the above (this in my experience is the most likely)
What I would advise, Steve, is to take lots of photos of the present screen (assuming that it's fitted correctly) and take the car to your favourite bodyshop (tell your insurer that this is what you intend to do - as with body repairs you can take the car where you want, you don't have to use their approved repairers). Tell the bodyshop that you want the new screen to be seated exactly as the current one and advise that you have photos. Strip off the outer rubber with the bodyshop man so you can see the relationship between the bodywork and the screen, for example, the gap between the body and the screen edge should be uniform and (I think) the plane of the glass is the same level as the plane of the abutting bodywork.
Sorry for such a long post but as you can gather I have been frustrated many a time on this issue.
Finally - good luck