Windshield: Service and Repair

SPECIAL TOOL(S)

REMOVAL

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

1. Remove the cowl grille.
2. Remove the interior rear view mirror.







3. Remove the instrument panel defroster opening grille.
1 Unclip the instrument panel defroster opening grille from the instrument panel.
2 Disconnect the electrical connectors.
3 Remove the instrument panel defroster opening grille.







4. Remove the windshield side garnish mouldings.
5. Remove the sun visors and sun visor Clips.
6. Partially remove the front door weatherstrips.
7. Lower the front portion of the headliner.
8. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld area.







9. Using the special tool, cut the urethane adhesive from the windshield starting at the top center and work toward the bottom corners.

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







10. Using the special tool, distance the windshield glass from the body.







11. Using the special tool, Cut the remaining urethane adhesive and remove the windshield glass.
12. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld area.

INSTALLATION

CAUTION: After installing a new urethane-installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (Refer to the Essex drive away chart for the cure times as the temperature and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive.

1. Dry fit the windshield glass. Make alignment marks with tape or nonstaining grease pencil.







2. Trim the remaining urethane adhesive on the pinch weld to within specification.

CAUTION: Avoid scratching the pinch weld area.

3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld area. Allow six to ten minutes to dry.
4. If reinstalling the original windshield glass, remove the excess urethane adhesive from the windshield glass.
5. Align the "V" notch in the ceramic paint and windshield outside molding at top center. Fully seat the windshield outside molding along the top edge of the windshield glass and along the sides and bottom edges of the windshield glass.

NOTE: If the molding is already on the windshield glass, proceed to the next step.

6. If installing a new windshield glass, clean the windshield glass with an alcohol-free based window cleaner to make sure the ceramic-coated area is clean.
7. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the surface to be urethaned.

NOTE: Wipe off the glass prep immediately after each application because it flash dries.

8. If installing a new windshield glass, apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was in the previous step. Allow five minutes to dry.







9. Cut the urethane adhesive applicator tip to specification.







10. Apply a bead of Urethane Adhesive Essex U-216 or Essex 400-HV meeting Ford specification WSB-M2G316-B to the pinch weld.

CAUTION: If the vehicle is to be driven within 24 hours of urethane application, Urethane Adhesive Essex U-216 must be used due to its one hour cure time.







11. Install the windshield glass aligning it to the marks made previously.
12. After the glass is set, check for water leaks and add urethane adhesive where needed.
13. Position the front portion of the headliner.
14. Install the front door weatherstrips.
15. Install the sun visors and sun visor clips.







16. Install the windshield side garnish mouldings.







17. Install the instrument panel defroster opening grille
1 Position the instrument panel defroster opening grille.
2 Connect the electrical connectors.
3 Install the instrument panel defroster opening grille

18. Install the rear view mirror.
19. Install the cowl grille.
20. Install and adjust the wiper blade and mounting arms.