Windshield: Service and Repair
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the antenna.
2. Remove the windshield wiper arms.
3. Remove the cowl vent panels.
4. Remove the inside rear view mirror.
5. Remove the A-pillar mouldings.
6. Lower the front portion of the roof trim panel.
7. Cover the seats, instrument panel and hood to prevent possible damage.
8. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinchweld area.
^ Use a clean rag or oil-free compressed air.
9. Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive.
NOTE: Refer to manufacturer's instructions before using the tool.
10. Insert the Interior Auto Glass Cut-Out Knife at the upper center of the windshield glass and work toward the bottom corners.
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING THE HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE.
CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinchweld during glass removal.
NOTE:
^ Insert the blade into the Cut-Out Knife so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the replacement windshield glass.
^ Support the windshield glass to prevent the glass from dropping while cutting the urethane adhesive.
11. To aid the in cutting the urethane adhesive along the cowl, insert the Pumper tool at the top center of the windshield and inflate.
12. Insert the Interior Auto Glass Cut-Out Knife into the bottom of the urethane adhesive and cut from corner to corner.
13. Carefully remove the windshield glass from the vehicle and place on a stable work surface.
WARNING: REMOVING THE WINDSHIELD GLASS REQUIRES MORE THAN ONE TECHNICIAN.
NOTE: If reinstalling the windshield glass, tape the windshield at the windshield stops to aid installation.
INSTALLATION
1. Dry-fit the new windshield glass on the existing urethane bead on the pinchweld.
1 Position the windshield glass on the pinchweld.
2 Center the windshield glass in the opening.
3 Adjust the setting blocks as needed for best fit.
4 Using tape or non-permanent marker, make alignment marks (preferably at the setting blocks) on the windshield glass and the body.
2. After the dry-fit alignment, remove the windshield glass and moulding assemblies and place on a stable work surface.
3. Trim the remaining urethane bead on the pinchweld to specification.
NOTE: The urethane must be smooth and free of cuts or contamination. Avoid touching the urethane surface after preparation.
4. Using a clean rag, brush or oil-free compressed air, to clean the pinchweld area around the existing urethane. Remove any foreign material or water that may have entered during windshield removal.
5. Check the pinchweld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that can cause glass damage. Clean or repair as necessary.
CAUTION: ALL rust found on the pinchweld must be removed and the pinchweld restored to OEM specifications. If surface rust is found, clean the area down to bare metal. Prime the affected area with OEM recommended curing automotive paint primer and allow to cure. If rust has penetrated the pinchweld metal, use bodyshop methods to repair the affected area before proceeding.
6. Apply Essex U413 Urethane Body Primer, Ford specification WSB-M2G234-C (black), to minor scratches or any bare metal on the pinchweld caused during removal.
^ Do not apply the primer to the existing urethane bed.
^ Allow the primer to dry for a minimum of 6-10 minutes before proceeding.
7. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane bead.
NOTE: If reinstalling the removed windshield glass, complete this step and go to step 10. If installing a new windshield glass, skip step 7 and go to step 8.
8. Clean the inside of the new windshield glass with an alcohol-free glass cleaner.
^ Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied.
9. Making the application approximately 25 mm (1 in) wide, apply two coats of Essex 401 Urethane Glass Primer, Ford specification WSB-M5B280-C2 (red), to the entire inside perimeter of the windshield glass.
^ Wipe off immediately after each application.
CAUTION:
^ Wipe off the red urethane glass primer immediately after application before it flash dries.
^ Make sure the area of red glass primer application aligns with the existing urethane bead on the pinchweld.
^ For correct installation, two coats of the red glass primer are necessary.
NOTE: Use a clean wool applicator for each application of the red glass primer.
10. Using a clean wool applicator, apply Essex 402 Urethane Glass Primer, Ford specification WSB-M2G314-B (black).
CAUTION:
^ The black urethane glass primer must be thoroughly mixed for even pigmentation.
^ The black glass primer must cure for a minimum of five minutes before the windshield glass is installed.
NOTE: The black glass primer application must be over the same area as the red primer application.
11. Install the inside rearview mirror.
12. Cut the applicator tip of Essex 400 HV or Essex U216 Urethane High Viscosity Adhesive, Ford specification WSB-M2G316-B, to specification. This will produce a triangular bead during application.
CAUTION: The urethane bead must have a triangular cross section.
NOTE: If Essex U216 is used, the vehicle may be released in one hour.
13. Apply a uniform 11-mm (0.43-inch) bead of Essex 400 HV or Essex U216 Urethane High Viscosity Adhesive, Ford specification WSB-M2G316-B, on top of the existing trimmed urethane bead on the pinchweld.
^ Make sure that all gaps in the urethane bead are smoothed into one continuous bead.
CAUTION: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
NOTE: If Essex U216 is used, the vehicle may be released in one hour.
14. Using the alignment marks made previously, position the windshield glass on the pinchweld.
WARNING: INADEQUATE OR INCORRECT CURING OF THE URETHANE ADHESIVE WILL ADVERSELY AFFECT WINDSHIELD GLASS RETENTION. AFTER INSTALLING URETHANE BONDED GLASS, THE VEHICLE MUST NOT BE DRIVEN UNTIL THE URETHANE HAS CURED. USING ESSEX 400 HV AT 21°C (700°F) AND RELATIVE HUMIDITY ABOVE 50%, ADEQUATE CURE TIME IS TYPICALLY 24 HOURS (LESS AT HIGHER TEMPERATURES AND HIGHER HUMIDITY). FOLLOW MANUFACTURER'S INSTRUCTIONS.
CAUTION:
^ Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the adhesive bond.
^ The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
NOTE: If Essex U216 is used the vehicle may be released in one hour.
15. Check the glass installation for air or water leaks.
16. Install the roof trim panel.
17. Install the A-Pillar mouldings.
18. Install the cowl vent panels.
19. Install the windshield wiper arms.
20. Install the antenna.