Windshield: Service and Repair

WINDSHIELD GLASS







SPECIAL TOOL(S)

REMOVAL

WARNING: To prevent glass splinters from entering eyes or cutting hands, wear safety glass and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury.







1. Open the four A-pillar passenger assist handle covers.







2. Remove the two A-pillar passenger assist handles.
1 Remove the four bolts.
2 Remove the two A-pillar passenger assist handles.







3. Remove the two windshield side garnish mouldings.







4. Remove the overhead console.
1 Open the front console door.
2 Remove the screws.
3 Remove the overhead console.
- If equipped, disconnect electrical connector.







5. Remove the two sun visors and two clips.
1 Remove the six screws
2 Remove the sun visors and clips.

6. Remove the driver and passenger assist handles.
7. Remove the interior rear view mirror.
8. Lower the front portion of the headliner.
9. Remove the cowl grille.
10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.







11. NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting.

Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and work toward the bottom corners.







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







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

INSTALLATION

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

1. Dry fit the windshield glass, making alignment marks with tape or non-staining grease pencil.







2. CAUTION: Do not scratch the pinch weld area.

Trim the remaining urethane adhesive on the pinch weld to within the specification.
- The existing urethane adhesive surface should be smooth and free of cuts and contamination.

3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry.
4. If reinstalling the original windshield glass, remove the excess urethane adhesive and the windshield moulding.
5. Clean the inside of the windshield glass surface with an alcohol-free cleaner making sure the ceramic coated area is clean.

6. NOTE: Wipe off the glass prep immediately after each application because it flash dries.

If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M5B280-C twice around the glass surface to be urethaned.

7. If installing a new windshield, apply Glass Primer Essex U-402 meeting Ford specification WSB-M2G314-B to the same area that was prepped in the pervious step. Allow five minutes to dry.







8. Apply foam dam meeting Ford specification WSB-M3G137-A to the bottom of the windshield glass.







9. Cut the urethane adhesive applicator tip to specification.







10. Apply a bead of Urethane Adhesive Essex 400-HV or Essex U-216, which meets Ford specification WSB-M2G316-B to the sides and top of the windshield glass.







11. Apply a bead of Urethane Adhesive Essex 400-HV which meets Ford specification WSB-M2G316-B to the bottom of the windshield glass outside the foam dam.







12. Install the windshield glass aligning it to the marks previously made.
13. After the windshield glass is set, check for water leaks and add urethane adhesive where needed.
14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass.
15. Install the cowl grille.
16. Reposition the front portion of the headliner.







17. Install the overhead console.
1 Position the overhead console.
- If equipped, connect the electrical connector.
2 Install the screws.







18. Install the two sun visors and two clips.
1 Position the sun visors and clips.
2 Install the six screws.

19. Install the interior rear view mirror.







20. Install the two windshield side garnish mouldings.







21. Install the two A-pillar passenger assist handles.
1 Position the two assist handles.
2 Install the four bolts.
3 Close the four assist handle covers.

22. Install the driver and passenger assist handles.