Windshield: Service and Repair

REMOVAL

WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT PERSONAL INJURY.

1. Remove windshield wiper arms and blades.
2. Remove inside rear view mirror.
3. Remove visors and drop headliner near windshield opening down to avoid cutting headliner during windshield removal. Place a small block of suitable material between headliner and roof to act as a spacer. Remove windshield side garnish moulding.
4. Remove cowl vent screen.
5. Remove inside rear view mirror.
6. Remove front door weatherstrip.









7. Use Rotunda Knife With Offset Blade 107-R1511, Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent to cut adhesive. Refer to manufacturer's instructions when using tool.

CAUTION: Use care to avoid damage to the instrument panel.

8. Remove windshield and moulding assemblies from vehicle using suitable suction tool.







9. Trim remaining urethane on pinch weld to within 1 to 1.5 mm (0.04 to 0.06 inch) thickness with utility knife or razor blade. When completed, surface should be smooth and free of cuts and contamination.
10. Check pinch weld sealing area for damaged sheet metal, rust or foreign objects which may have caused, or may cause, glass breakage. Service metal if necessary.

INSTALLATION
1. If painted sheet metal has been exposed anywhere along the flange, use the supplied wool applicator and apply Urethane Metal Primer WSB-M2G234-C to windshield pinch weld.

NOTE: A minimum of 10 minutes is required for primer surface to dry.

2. Install foam dam (with self-adhesive backing) around windshield glass opening at end of metal flange, and at uppermost side of seal area.
3. Place windshield glass and moulding assembly on a low, stable work surface, inside up.

If moulding is already on glass, proceed to Step 4.

If moulding needs to be installed, use this procedure:
- Align V-shaped notch in ceramic paint and windshield outside moulding at top center. Fully seat windshield outside moulding along the top edge of windshield glass, then work along sides and bottom edges of the windshield glass.

4. Clean windshield with Ford Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA or equivalent meeting Ford specification ESR-M14P5-A.
5. Using a clean wool applicator, wipe inside glass edge with Urethane Glass Prep WSB-M5B280-C2 21 mm (0.8 inch) wide along top and sides and 70 mm (2.75 inches) wide along bottom. Wipe off glass prep and repeat prep application.

NOTE: Wipe off Urethane Glass Prep WSB-M5B280-C2 immediately after application because it flash dries. Prep application must be applied twice.

6. Properly align windshield glass to body.
a. Place windshield glass into opening. Center it top and bottom, side-to-side. Adjust lower glass stops if necessary.
b. Using masking tape or crayon, make alignment marks at points on four sides of both glass and window opening.
7. Remove windshield glass and moulding assemblies from vehicle and place it back on work table.
8. Thoroughly shake and stir Urethane Glass Primer WSB-M2G314-B to make sure of uniform pigment mixing.
9. Using a clean wool applicator, apply primer to inside glass edge 21 mm (0.8 inch) wipe along top and sides and 70 mm (2.75 inches) wide along bottom.

NOTE: Allow a minimum of 5 minutes for glass primer to dry.







10. Apply an even bead of Urethane Adhesive WSB-M2G316-B around entire sheet metal pinch weld next to windshield moulding retaining leg. The bead should be triangular in shape, 16 mm (0.63 inch) high and 8 mm (0.3 inch) at base.

NOTE:
- Leave a door window slightly open until adhesive is cured.
- Apply new urethane on top of existing material on pinch weld.

11. Install windshield assembly onto vehicle, taking care to align marks on glass to marks on body. This must be done before adhesive skins over.
12. Remove spacer and install headliner, windshield wiper arms, blades, cowl vent screen, visors and windshield side garnish moulding.
13. Install inside rear view mirror.

CAUTION:
- Use only urethane for service of air and water leaks in urethane-set windshield.
- When replacing urethane-installed glass parts, do not drive the vehicle until the urethane has cured. At temperatures above 13°C (55°F) and relative humidities above 50%, adequate cure time is typically 12 to 24 hours (less at higher temperatures and lower humidities). See detailed instructions provided by the urethane manufacturer. Inadequate or improper curing can adversely affect the retention of the windshield.

14. Check installation for air and water leaks in urethane seal.