Antenna: Service and Repair
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, there are two methods for repairing grid breaks:^ Method I utilizes Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A with Touch-Up Exterior Paint AL81-5477-B or equivalent meeting Ford specification ESR-M2P100-C if required.
^ Method II utilizes a commercially available epoxy adhesive and does not require touch-up of the first (brown) layer if damaged or missing.
The epoxy service kit is available from:
Marketing East Company
10 Liberty Street
North Andover, Massachusetts 01845
Telephone: (508)689-9565
There are also two methods for repairing terminal separation from glass:
^ Method I involves soldering the terminal to the glass.
^ Method II uses a commercially available epoxy adhesive.
Surface Preparation-Method I
1. If necessary, bring vehicle inside and warm it to 16°C (60°F) or above.
NOTE: If the first layer of the heated back window glass grid (brown) is damaged or missing, it will be necessary to apply brown Touch-Up Exterior Paint AL81-5477-B or equivalent meeting Ford specification ESR-M2P100-C on the glass prior to applying the Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A.
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-Method I
NOTE: Make sure bottle of Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A and touch-up paint (if needed) are at room temperature. Shake bottle for at least one minute for thorough mixing. Shake bottle frequently during use.
Application-Method I
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 scraping gently toward grid.
CAUTION: Be careful not to damage grid line with razor blade. Additional repairs may be necessary.
Curing-Method I
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.
Surface Preparation-Method II
1. If necessary, the vehicle should be brought inside and warmed to 16° (60°F) or above.
2. Clean entire grid line repair 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 cleaners on the interior surface of the back window glass as this may cause damage to the grid lines.
Mixing-Method II
1. Check expiration date of package. If hardener has crystallized, place package in hot water until the hardener softens.
2. Remove plastic clamp from package separating resin and hardener.
3. Knead package until resin and hardener are thoroughly mixed.
4. Cut corner of package to open.
Application-Method II
1. Mark location of break on outside of back window glass.
2. Place masking tape (provided in kit) over break in grid wire, aligning holes in masking tape with grid wire.
3. Apply two-part epoxy, with stick provided, to wire grid break through cut-out in masking tape.
4. Carefully remove masking tape from grid wire repair area.
Curing-Method II
1. Using Rotunda Heat Gun 107-R0300 or equivalent, heat grid wire repair area for one to two minutes.
NOTE: Care should be taken while using heat gun around interior trim.
2. Start engine, turn heated back window switch and light on and leave on for five minutes. Inspect grid wire repair area.
NOTE: Heated back window is now operational. Two-part epoxy will thoroughly cure in 24 hours.
Bus Terminal Service-Method I
1. Allow the back window glass to warm up to room temperature for one-half hour to an hour.
2. Clean the bus bar in the area to be serviced using fine steel wool (3/0 to 4/0 grade).
3. Restore the area where the bus bar terminal was originally attached by applying three coats of Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A. Allow approximately 10 minutes drying time between coats.
4. Working as quickly as possible to avoid overheating the back window glass, tin the bus bar with solder in the area where the terminal will be reattached.
5. Using Rotunda Heat Gun 107-R0300 or equivalent, preheat the back window glass in the solder area to 67°-83°C(153°-181°F) just prior to soldering the terminal on.
6. Position the terminal on the bus bar in the area that was tinned and hold it in place with an ice pick or screwdriver.
7. Apply soldering heat to the pad of the terminal until the solder flows.
CAUTION: To avoid damaging the bus bar, remove the soldering gun or Iron as soon as the solder flows.
8. Start the vehicle. Turn the heated back window switch and light on and leave on for five minutes. Inspect the terminal and apply Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A to the required area.
Bus Terminal Service-Method II
1. Allow back window glass to warm up to room temperature for one-half hour to an hour.
2. Clean bus bar in area to be repaired using fine steel wool (3/0 to 4/0 grade).
3. Apply masking tape to bus bar around bus bar terminal location.
4. Prepare service kit two-part epoxy.
a. Check expiration date of package. If hardener has crystallized, place package in hot water until the hardener softens.
b. Remove plastic clamp from package separating resin and hardener.
c. Knead package until resin and hardener are thoroughly mixed.
d. Cut corner of package to open.
5. Apply two-part epoxy, with stick supplied, to bus bar terminal location of bus bar.
6. Using a screwdriver, position bus bar terminal to bus bar.
7. Using Rotunda Heat Gun 107-R0300 or equivalent, heat bus bar terminal and two-part epoxy for one to two minutes while holding bus bar terminal in position.
NOTE: Care should be taken while using heat gun around interior trim.
8. Carefully remove masking tape.
9. Carefully install wire to terminal. Heated back window is now operational. Two-part epoxy will thoroughly cure in 24 hours.
10. Start engine. turn heated back window switch and light on and leave on for five minutes. Inspect bus bar terminal repair.