Method I

NOTE: There are two methods for repairing terminal separation from glass and/or grid breaks. Method I involves soldering the terminal to the glass and Method II uses an epoxy adhesive.

1. Allow the back window glass to warm up to room temperature for 30-60 minutes.
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 (120°-150°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 it 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.