Windshield: Service and Repair

REMOVAL
1. Remove windshield wiper arms and blades.
2. Remove windshield outside moulding.

WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN.

3. Remove visors and drop headliner near windshield opening down to avoid cutting headliner during windshield removal. Place a small block of suitable material between headliner and roof to act as a spacer. Remove windshield garnish moulding as required.
4. Remove LH and RH cowl vent screens.
5. Remove inside rear view mirror.












6. Use Rotunda Knife With Offset Blade 107-R1511, Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent to cut adhesive. Refer to manufacturer's instructions when using tool.

CAUTION: Use care to avoid damage to the instrument panel.

NOTE: A long-bladed knife is needed to cut two rows of urethane along bottom of windshield glass.







7. Remove windshield and moulding assemblies from vehicle using suitable suction tool.
8. Trim remaining urethane on pinch weld to within 1 to 1.5 mm (0.04 to 0.06 inch) thickness with utility knife or razor blade. When completed, surface should be smooth and free of cuts and contamination.
9. 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 flange use the supplied wool applicator and apply Urethane Metal Primer or equivalent meeting Ford specification WSB-M2G234-C to windshield pinch weld.

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

2. Place windshield and moulding assembly on a low, stable work surface, inside up.
3. Clean windshield with ammonia-based glass cleaner.
4. Using a clean wool applicator, wipe inside glass edge with Urethane Glass Prep or equivalent meeting Ford specification WSB-M5B280-C2, 21 mm (0.8 inch) wide along top and sides and 70 mm (2.75 inch) wide along the bottom. Wipe off glass prep and repeat prep 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.

5. Install foam dam (with self-adhesive backing) on pinch weld about 9.0 mm (0.35 inch) from edge of windshield glass. At bottom of windshield glass, install 50 mm (2 inches) from bottom edge of windshield glass.
6. Properly align windshield glass to body.
a. Place windshield glass into opening. Center it top and bottom, side-to-side (adjust lower glass stops it necessary).
b. Using masking tape or crayon, make alignment marks at points on four sides of both glass arid window opening.
7. Remove windshield 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 16 mm (0.6 inch) wide along top and sides and 70 mm (2.75 inches) wide along bottom.

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

10. Apply an even bead of urethane WSB-M2G316-B around entire sheet metal pinch weld next to windshield 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 on pinch weld.

11. Install windshield assembly onto vehicle. This must be done before adhesive skins over.
12. Install retainers and moulding.
13. Remove spacer and install headliner, visors, windshield wiper arms, blades, and windshield garnish moulding.
14. Install cowl vent screens.
15. Install inside rear view mirror.

CAUTION:
- Use only urethane for service of air and water leaks in urethane set windshield.
- 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 windshield.

16. Check installation for air and water leaks in urethane seal.
17. Install windshield outside moulding.