Windshield: Service and Repair

SPECIAL SERVICE TOOL(S)

REMOVAL

WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING GLASS FROM THE VEHICLE.

1. Remove the LH and RH windshield side garnish mouldings.







2. Remove the LR and RH sun visors and clips.
3. Lower the front portion of the headliner.
4. Remove the interior rear view mirror. For additional information, refer to Mirrors.
5. Remove the wiper pivot arms. For additional information, refer to Wiper and Washer Systems.
6. Remove the cowl grille.
7. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld.







8. Using the special tool start at the top center of the windshield cut the urethane sealant away from the glass and work down the sides.

CAUTION: Care must be used to avoid scratching the pinch weld.

NOTE: Lubricate the existing urethane sealant with water to aid the special tool while cutting.







9. Using the special tool, distance the windshield from the body.







10. Using the special tool, cut the urethane sealant and remove the windshield.
11. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.

INSTALLATION

CAUTION: After installing the new urethane-installed glass, the vehicle should not be driven until the Urethane Sealant has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the Urethane Sealant may adversely affect the strength of the Urethane Sealant bond.

1. Dry-fit the windshield glass by centering it side-to-side and by adjusting the setting blocks (if equipped) to get the correct position of the part top-to-bottom. Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body.







2. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane is removed leaving a level bead around the entire pinch weld.

CAUTION: Care must be taken to avoid scratching the pinch weld.

3. Use the wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to ten minutes to dry.







4. Apply foam tape along the top edge of the cowl pinch weld.
5. If reinstalling the original windshield, remove the excess urethane sealant from the windshield glass.
6. If installing a new windshield glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.

7. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be prepped.

CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area.

8. Apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the previous step. Allow five to minutes to dry.







9. Cut the urethane applicator tip to specification.







10. Apply a bead of Urethane Sealant Essex 400-HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld just outside the foam tape dam.

CAUTION: If vehicle is to be driven within 24 hours of urethane sealant application, Urethane Sealant Essex U-216 meeting Ford specification WSB-M2G3 16-B must be used due to its one hour cure time.

11. Using the alignment marks, install the windshield glass.

CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed.

12. After the urethane sealant has cured, check for water leaks and add urethane sealant where needed.
13. Install the front portion of the headliner.
14. Install the RH and LH windshield side garnish mouldings.
15. Install the sun visors and clips.
16. Install the interior rear view mirror. For additional information, refer to Mirrors.
17. Install the cowl grille.
18. Install the wiper pivot arms. For additional information refer to Wiper and Washer Systems.