Method I

A single break or any breaks that total 25 mm (1 Inch) in one grid cannot be serviced. The back window glass must be replaced. For breaks less than 25 mm (1 Inch) long, use the following procedure:

NOTE: If the first layer of the heated back window glass grid (brown) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81-5477-B or equivalent meeting Ford specification ESR-M2P100-B on the glass prior to applying the Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A.

Service inoperative grid wires on back window glass using Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A as follows.

Surface Preparation
1. Bring vehicle inside and warm it to 16°C (60°F) or above.
2. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry.

CAUTION: Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the back window glass as this may cause damage to the grid lines.

Mixing
The bottle of Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A and touch-up paint (if needed) must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use.







Application
1. Mark location of break on the outside of the back window glass.
2. Using cellulose tape, mask off the area directly above and below grid break. The break area should be at the center of the mask and tape gap must be no wider than the existing grid line.
3. Apply the correct coating in several smooth continuous strokes (allowing three to five minutes drying time between coats) across the break area using the brush applicator in the cap. Extend the service coating at least 6.35 mm (1/4 Inch) on both sides of the break area.

If both brown and silver layers of the grid are broken or missing, apply a coating of the brown touch-up paint across the break area first. Two coats may be necessary to obtain the proper color. Allow the touch-up paint to dry then apply three coats of grid repair compound allowing three to five minutes drying time between coats. The coating of the grid repair compound should extend at least 6.35 mm (1/4 Inch) on both sides of the break area.

NOTE: If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the break.

4. Allow to dry for five minutes then remove the mask.
5. After removing the mask, check the outside appearance of the grid repair compound. If the repair compound is visible above or below the grid, this excess should be removed. This can be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid.

CAUTION: Be careful not to damage grid line with razor blade. Additional repairs may be necessary.

Curing
The service coating will air-dry in approximately one minute and can be energized within three minutes. Optimum hardness and adhesion occurs after approximately 24 hours. At that time, the serviced area may be cleaned with a mild window cleaner.