Windshield Glass
Windshield Glass
NOTE: Taurus shown, all others similar.
Removal
1. Remove the A-pillar trim panels.
2. Remove the interior mirror.
3. Partially lower the front headliner near the windshield header and block with suitable material.
4. Remove the cowl panel grille.
5. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or otherwise damage the pinch weld during glass removal.
NOTE: Insert the blade into the Deluxe Windshield Remover Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement windshield glass.
NOTE: Lubricate the existing urethane adhesive with water to aid the Deluxe Windshield Remover Tool) while cutting.
NOTE: Removing the windshield glass requires more than one technician.
Using the Deluxe Windshield Remover Tool, cut the urethane adhesive from the windshield glass starting at the top center and working toward the bottom corners.
6. Using The Pumper, distance the windshield glass from the body.
7. Using the Deluxe Windshield Remover Tool, cut the remaining urethane adhesive and remove the windshield glass.
Installation
NOTE: For additional material guidelines, refer to the manufacturer's installation information.
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. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinch weld.
5. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
6. If installing the original windshield glass, remove the excess urethane adhesive.
7. Clean the inside of the windshield glass surface with glass cleaner.
8. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material chart in this procedure.
If installing a new windshield glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
9. Cut the urethane adhesive applicator tip to specification.
10. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and continuous bead.
Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield near the center, making sure there are no gaps in the bead.
11. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.
Install the windshield glass on the vehicle aligning it with the markings made previously.
12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
After the urethane adhesive has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
13. Install the cowl panel grille.
14. Install the headliner.
15. Install the interior mirror.
16. Install the A-pillar trim panels.