Attachment III - Technical Information

OVERVIEW

This procedure for windshield replacement includes revisions to the published workshop manual which must be followed. The primers and urethane used for this recall have been approved to allow a faster cure time. These revisions will be included in the next CD/DVD update to the 2002 and 2003 Model Year Taurus/Sable Workshop Manuals. Go to either the 2002 or 2003 manual for section references found in this procedure.

SERVICE PROCEDURE





SPECIAL TOOL(S)





MATERIALS

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 cowl grille. For additional information, refer to Section 501-02.

2. Remove the interior rearview mirror.

For additional information, refer to Section 501-09.

3. Position the LH and RH front door weatherstrips aside.





4. Remove the LH and RH windshield side garnish mouldings.

5. Remove the eight screws, the LH and RH sun visors and the two (2) sun visor clips.





6. If equipped remove the dome lamp assembly. For additional information, refer to Section 417-02.

7. Partially lower the headliner near the windshield opening and block with suitable material.

8. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

9. NOTE: Lubricate the urethane adhesive with water to aid the special tool in cutting the urethane.





Using the special tool, place the flat side of the knife against the windshield glass. Start at the top center of the windshield glass and work out and down the pillars to the lower corners.





10. Install the special tool into the top of the windshield glass and inflate. Cut the urethane adhesive from corner to corner along the bottom of the windshield glass.

11. Remove the windshield glass.

12. 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 a minimum of two (2) hours. Inadequate or incorrect curing can adversely affect the retention of the windshield.

1. Dry fit the windshield glass to the existing urethane adhesive bead on the body pinch weld. Align the windshield glass in the opening for a uniform fit.

2. Use a non-permanent pencil to make alignment marks on the windshield glass at the setting blocks and the body to aid in the installation alignment of the windshield glass.

3. Remove the windshield glass.

4. NOTE: Avoid scratching the pinch weld.





Trim the remaining urethane adhesive on the pinch weld, be sure to leave a layer of urethane approximately 1-2 mm thick on the flange. The urethane adhesive must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.

5. Apply urethane metal primer to minor scratches or exposed metal on the pinch weld caused during removal. Do not apply primer to the existing urethane adhesive.

6. CAUTION: Cleaning the inside of the glass with a non-alcohol based cleaner is absolutely necessary for proper adhesion.

Clean the inside of the windshield glass surface with a non-alcohol based glass cleaner.

7. On the new windshield, apply the one-step primer to the area on the windshield where the urethane will make contact. Allow five (5) to seven (7) minutes to dry.





8. Cut the urethane adhesive applicator tip to specifications.

9. NOTE: Use either a high ratio caulk gun or an electric or battery powered caulk gun to apply the urethane using less effort. Warming the tube of urethane undera 100 watt bulb for a few minutes will also help when dispensing it from the tube.





Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.

10. Install the windshield glass on the vehicle aligning it with the markings made previously.

11. Installation may be checked for leaks using Rotunda Ultrasonic Leak Detector 134-R0135 along with Signal Transmitter 134-R0136 or equivalents. Do NOT use water to test freshly applied urethane.

12. Position the headliner.

13. If equipped, install the dome lamp assembly. For additional information, refer to Section 417-02.





14. Install the two sun visor clips, the LH and RH sun visors, and the eight screws.





15. NOTE: When installing the windshield side garnish mouldings, be sure the alignment tabs are positioned correctly.

Install the RH and LH windshield garnish mouldings.

16. Install the RH and LH front door weatherstrips.

17. Install the interior rear view mirror. For additional information, refer to Section 501-09.

18. Install the cowl grill. For additional information, refer to Section 501-02.