Windshield Glass

WINDSHIELD GLASS

Special Tool(s):

Special Tool(s)

Removal
1. Remove the cowl vent grille.
2. Remove the interior rear view mirror.
3. Remove the windshield side garnish mouldings.
4. Remove the overhead console.
5. Remove the inside visor.
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. NOTE: Refer to manufacturer's instructions before using the tool.

Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive.







10. 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.

Insert the Interior Auto Glass Cut-Out Knife at the upper center of the windshield glass and work toward the bottom corners.







11. To aid the tool 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. 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 in alignment of the glass during installation.

Carefully remove the windshield glass from the vehicle and place on a stable work surface.

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 glass and moulding assembly from the windshield opening and place on a stable work surface with the interior side of the glass facing up.
3. 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.







4. NOTE: The urethane must be smooth and free of cuts or contamination. Avoid touching the urethane surface after preparation.

Trim the remaining urethane bead on the pinchweld to specification.

5. 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 body shop methods to repair the affected area before proceeding.

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.

6. Apply Essex U413 Urethane Body Primer, Ford specification WSB-M2G234-C, 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. 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.

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.

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. CAUTION:
- Wipe off the urethane glass prep immediately after application before it flash dries.
- Make sure the area of glass prep application aligns with the existing urethane bead on the pinchweld.
- For correct installation, two coats of the glass prep are necessary.

NOTE: Use a clean wool applicator for each application of the glass prep.

Making the application approximately 25-mm (1-in) wide, apply two coats of Essex 401 Urethane Glass Prep, Ford specification WSB-M5B280-C2, to the entire inside perimeter of the windshield glass.
- Use a clean shop towel to wipe the glass prep off immediately after each application.

10. CAUTION:
- The urethane glass primer must be thoroughly shaken for proper curing to occur.
- The glass primer must cure for a minimum of five minutes before the windshield glass is installed.
- Do not allow the glass primer to come in contact with the moulding. Keep the primer application 2-3 mm (0.07-0.11 in) away from the edge of the moulding.

NOTE: The glass primer application must be over the same area as the glass prep application.

Using a clean wool applicator, apply Essex 402 Urethane Glass Primer, Ford specification WSB-M2G314-B.







11. CAUTION: The urethane bead must have a triangular cross section.

Cut the applicator tip of Essex 400 HV Urethane High Viscosity Adhesive, Ford specification WSB-M2G316-B, to specification. This will produce a triangular bead during application.

12. CAUTION: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.

Apply a uniform 11-mm (0.43-inch) bead of Essex 400 HV 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.

13. 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 (70°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.

Using the alignment marks made previously, position the windshield glass on the pinchweld.

14. Check the glass installation for air or water leaks.
15. Install the roof trim panel.
16. Install the inside visor.
17. Install the overhead console.
18. Install the windshield side garnish mouldings.
19. Install the interior rear view mirror.
20. Install the cowl vent grille.