Removal and Replacement

REMOVAL
1. Disconnect rear window defroster wires.
2. Remove interior garnish mouldings and drop headliner near back window to avoid cutting headliner during back window removal. Place a small block of suitable material between headliner and roof to act as a spacer.

WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN.












3. Use Rotunda Knife with Offset Blade 107-R1511 and Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalents to cut adhesive. Refer to manufacturer's instructions when using tool.

CAUTION: Use care to avoid damage to the rear package tray cover panel.







4. Remove back window glass and moulding assemblies from vehicle using suitable suction tool.
5. Trim remaining urethane on pinch weld to within 1 and 1.5 mm (0.04 and 0.06 inch) thickness with utility knife or razor blade. When completed, surface should be smooth and free of cuts and contamination.
6. Check pinch weld sealing area for damaged sheet metal, rust or foreign objects which may have caused, or may cause, glass breakage. Service metal as required.

INSTALLATION
1. If painted sheet metal has been exposed anywhere along the pinch weld, use the supplied wool applicator and apply Urethane Metal Primer or equivalent meeting Ford specification WSB-M2G234-C to rear window pinch weld.

NOTE: A minimum of 10 minutes is required for primer surface to dry.

2. Place back window and moulding assembly on a low stable work surface, inside up.

NOTE: If a new back window glass is to be installed, attach new moulding to edge of glass starting at top center working out, then down pillars and around lower corners.

3. Install foam dam (with self-adhesive backing) inside edge of pinch weld.
4. Clean back window with ammonia-based glass cleaner.
5. Using a clean wool applicator, wipe inside glass edge with Urethane Glass Prep or equivalent meeting Ford specification WSB-M5B280-C2, 12.7 mm (0.8 inch) wide along top and sides 30 mm (1.2 inches) wide along bottom. Wipe off glass prep and repeat application.

NOTE: Wipe off Urethane Glass Prep or equivalent meeting Ford specification WSB-M5B280-C2 immediately after application because it flash dries. Prep application must be applied twice.

6. Properly align back window glass to body.
a. Place back window glass into opening. Center it top and bottom, side-to-side (adjust lower glass stops, if necessary).
b. Using masking tape or crayon, make alignment marks at points on four sides of both glass and window opening.
7. Remove back window glass and moulding assemblies from vehicle and place it back on work table.
8. Thoroughly shake and stir Urethane Glass Primer or equivalent meeting Ford specification WSB-M2G314-B to make sure of uniform pigment mixing.
9. Using a clean wool applicator, apply primer to inside glass edge 12.7 mm (0.8 inch) wide along top and sides and 30 mm (1.2 inches) wide along bottom.

NOTE: Allow a minimum of five minutes for glass primer to dry.

10. Apply an even bead of Urethane or equivalent meeting Ford specification WSB-M2G316-B around entire sheet metal flange next to back window moulding retaining leg. The bead should be triangular in shape 16 mm (0.625 inch) high and 8 mm (0.33 inch) at base. Apply two rows of urethane along cowl top.

NOTE:
- Leave a door window slightly open until adhesive is cured.
- Apply new urethane on top of existing material in pinch weld.

11. Install back window glass onto vehicle, taking care to align marks on glass to marks on body. This must be done before adhesive skins over.

CAUTION: When replacing urethane installed glass parts, the vehicle should not be driven until the urethane has cured. At temperatures above 13°C (55°F) and relative humidities above 50%, adequate cure time is typically 12 to 24 hours (less at higher temperatures and lower humidities). See detailed instructions provided by the urethane manufacturer. Inadequate or improper curing may adversely affect the retention of the back window glass.

12. Reconnect rear window defroster wires.
13. Remove spacer and install headliner. Install retainers and back window upper garnish moulding.
14. Apply tape from top and sides of back window glass to roof to hold back window glass in place until urethane cures.
15. Check installation for air and water leaks in urethane seal.

CAUTION: Use only urethane for service of air and water leaks in urethane-set back windows, or deterioration of urethane may result.