Back Window Glass: Service and Repair
REMOVALWARNING: 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: Do not scratch the pinch weld.
1. Remove the package tray trim panel.
2. Disconnect the three back window glass electrical connectors:
^ two rear defrost electrical connectors.
^ FM antenna electrical connector.
3. If equipped, disconnect the cellular phone antenna connector.
4. Lower the rear portion of the headliner.
5. Using a soft brush or vacuum, remove the dirt and foreign material from tile pinch weld.
6. Using the special tool, starting at the top center of the back window glass, cut the sealant away from the glass and work down the sides.
CAUTION: Care must be taken to avoid scratching the pinch weld.
NOTE: Lubricate the existing urethane sealant with water to aid the special tool while cutting.
7. Using the special tool, distance the back window glass from the body.
8. Using the special tool, cut the remaining urethane sealant and remove the back window glass.
9. Using a soft brush or vacuum, remove the 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 replacement back window glass to the existing urethane bed on the body pinch weld. Align the back window glass in the opening for uniform fit.
2. Use tape or non-permanent marking pencil to make alignment marks on the back window glass (preferably at the setting blocks), and the body to aid in the installation alignment of the replacement back window glass.
3. After alignment, remove the back window glass and molding assemblies from the vehicle and place on a stable work surface.
4. 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.
5. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair surface as necessary.
WARNING: ALL RUST FOUND ON THE PINCH WELD MUST BE REMOVED AND THE PINCH WELD RESTORED TO OEM SPECIFICATIONS. IF SURFACE RUST IS FOUND, REMOVE COMPLETELY DOWN TO CLEAN, BARE METAL. PRIME PINCH WELD METAL WITH AN OEM RECOMMENDED CURING AUTOMOTIVE PAINT PRIMER AND ALLOW TO CURE PROPERLY. IF RUST HAS PENETRATED THROUGH THE PINCH WELD METAL, REPAIR THE PINCH WELD SHEET METAL AT A BODY SHOP BEFORE PROCEEDING.
6. 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.
7. If reinstalling the original back window glass, remove any excess urethane sealant.
8. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
9. If installing a new back window glass, 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.
10. If installing a new back window glass, 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 minutes to dry.
11. Cut the urethane applicator tip to specification.
12. Apply a bead of Urethane Sealant Essex 400-HV or Essex U-216, meeting Ford specification WSB-M2G316-B to the pinch weld.
CAUTION: If the vehicle is to be driven within 24 hours of urethane sealant application, Urethane Sealant Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one-hour cure time.
13. Install the back window glass on the pinch weld. Align the back window glass to the body using the alignment marks while pushing downward to set the stops.
CAUTION: Open the windows to prevent the back window glass from being pushed out by air pressure if a door is closed.
14. Inspect the back window glass for air or water leaks and add urethane sealant where needed.
15. If equipped, install the cellular phone antenna. For additional information, refer to cellular Phone.
16. Connect the three back window electrical connectors:
^ two rear defroster connectors.
^ FM antenna electrical connector.
17. Install the package tray trim panel.