Back Window Glass: Service and Repair
SPECIAL SERVICE TOOL(S)
REMOVAL
WARNING: 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.
1. Remove the high mount stop lamp. For additional information, refer to Lighting and Horns.
2. Disconnect the LH and RH rear window defroster grid electrical connectors.
3. Lower the headliner near the back window glass and support it with a suitable support.
4. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
5. Using the special tool, place the flat side of the knife against the back window glass. Start at the top and work towards the comers.
NOTE: Lubricate the urethane sealant with water to aid the special tool when cutting the urethane sealant.
6. Install the special tool into the top of the back window glass and inflate. Cut from comer to comer along the bottom of back window glass.
7. Remove the back window glass.
8. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
INSTALLATION
CAUTION: When installing urethane installed glass parts, the vehicle must not be driven until the urethane has cured. At temperatures above 21°C (70°F) and relative humidity above 50%, adequate cure time is typically 24 hours (less at higher temperatures and higher humidities). See detailed instructions provided by the urethane manufacturer. Inadequate or incorrect curing can adversely affect the retention of the back window glass.
NOTE: On Taurus vehicles only, allow for a 5mm gap between roof, body sides and the back window glass.
1. Dry fit the back window glass to the existing urethane sealant on the body pinch weld. Align the glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks to aid in the installation alignment of the new glass.
3. Trim the urethane sealant on the pinch weld. The urethane sealant must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane sealant surface after preparation.
NOTE: Avoid scratching the pinch weld area. A portion of the pinch weld will be visible once the rear widow glass is installed.
4. Apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed or damaged metal on the pinch weld.
5. If installing the original back window glass, remove the excess urethane sealant.
6. Clean the back window glass with a non-alcohol based window cleaner.
7. If installing a new back window glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice to the area to be urethaned.
CAUTION: Wipe off the Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B immediately after each application because it flash dries.
8. 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 in the previous step. Allow five minutes to dry.
9. Cut the urethane sealant applicator tip to specification.
10. Apply Urethane Sealant Essex U-216 or Essex 400-HV meeting Ford specification WSB-M2G316-B on top of the existing urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane sealant are smoothed into one continuous bead.
CAUTION: If the vehicle is to be driven within 24 hours of urethane sealant application, Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time.
11. Install the back window glass on the pinch weld. Align the back window glass to the body using the alignment marks.
NOTE: On Sable vehicles only, adjust the back window glass on the setting blocks.
12. Inspect the back window glass for air or water leaks through the urethane seal.
13. Install the headliner.
14. Connect the LH and RH rear window defroster connectors.
15. Install the high mount stop lamp. For additional information, refer to Lighting and Horns.