Windshield: Service and Repair

SPECIAL TOOL(S)

REMOVAL

WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

1. Remove the windshield wiper pivot arms.
2. Remove the cowl grille.







3. Remove the sun visors and clips.







4. Remove the windshield side garnish mouldings.







5. Remove the instrument panel defroster opening grille.
^ If equipped, disconnect the electrical connectors.
6. Cover the defroster openings with tape to prevent contaminants from entering the defroster housing.
7. Remove the interior rear view mirror.
8. Lower the front portion of the headliner.
9. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.







10. Using the special tool, starting at the top center of the windshield glass cut the urethane adhesive from the glass and work down the sides.

CAUTION: Care must be taken to prevent scratching the pinch weld.

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







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







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

INSTALLATION

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

1. Dry-fit the windshield glass by centering it side-to-side and by adjusting the blocks (if equipped) to get the correct position of the part top-to-bottom. Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body.







2. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane is removed leaving a level bead around the entire pinch weld.

CAUTION: Care must be taken to avoid scratching the pinch weld.

3. Using a wool applicator, apply the Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M234-C to any exposed metal on the pinch weld and allow six to ten minutes to dry.
4. If reinstalling the original windshield glass, remove any excess urethane adhesive from the glass.
5. If installing a new windshield glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
6. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be prepped.

CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area.

7. If installing a new windshield 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.







8. Cut the applicator tip to specification.







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

CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, Urethane Adhesive Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its two and one-half hour cure time.

10. Using the alignment marks install the windshield glass.

CAUTION: Open a window to prevent the windshield glass from being pushed out by air pressure when a door is closed.

11. After the glass is set, check for water and air leaks through the urethane adhesive and add urethane adhesive where needed.
12. Install the front portion of the headliner.
13. Install the interior rear view mirror.
14. Remove the tape from the defroster housing.







15. Install the instrument panel defroster opening grille assembly.
^ If equipped, connect the electrical connectors.







16. Install the windshield side garnish mouldings.







17. Install the sun visors and clips.
18. Install the cowl grille.
19. Adjust the windshield wiper pivot arms.