Method I

NOTE:
^ There are two methods for repairing terminal separation from glass and/or grid breaks. Method I involves soldering the terminal to the glass and Method II uses an epoxy adhesive. Also, grid line repair procedures are different.
^ Any break in the grid longer than 25 mm (1 inch) cannot be serviced. The back window glass must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure:
^ If the first layer of the heated back window grid (brown) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81-5477-B or equivalent meeting Ford specification ESR-M2P100-B on the back window glass prior to applying the Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A.

Surface Preparation
1. The vehicle should be brought inside and warmed to 16°C (60°F) or above.
2. Clean entire grid line repair area with Ultra-Clear Spray Glass Cleaner E4AZ-19C507-AA or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil, or other foreign matter. It is important that repair area be clean and dry.

CAUTION: Do not use scrapers sharp instruments or abrasive cleaners on the interior surface of the back window glass as this may cause damage to grid lines.

Mixing

NOTE: The bottle of Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A and touch-up paint must be at room temperature.

Shake bottle for at least one minute for thorough mixing. Shake frequently during use.

Application
1. Mark location of break on outside of back window glass.






2. Using cellulose tape, mask off area directly above and below grid break. The break area should be at the center of the mask and tape gap must be no wider than existing grid line.
3. Apply the repair coating in several smooth, continuous strokes (allowing three to five minutes drying time between coats) across the break area using the brush applicator in the cap. Extend the service coating at least 6.35 mm (1/4 inch) on both sides of the break area.

If both brown and silver layers of grid are broken or missing, apply a coating of the brown touch-up paint across break area first. Two coats may be necessary to obtain proper color. Allow touch-up paint to dry. Then apply three coats of grid repair compound, allowing three to five minutes drying time between coats. The coating of grid repair compound should extend at least 6.35 mm (1/4 inch) on both sides of break area.

NOTE: If the brown layer of the grid is not broken or missing, apply only the grid repair compound to the break.

4. Allow to dry for five minutes, then remove mask.
5. After removing mask, check outside appearance of grid repair. If repair compound is visible above or below grid, this excess should be removed. This can be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid.

CAUTION: Be careful not to damage the grid line with the razor blade. Further repairs may be necessary.

Curing
The repair coating will air-dry in approximately one minute and can be energized within three to five minutes. Optimum hardness and adhesion occurs after approximately 24 hours. At that time, the repair area may be cleaned with a mild window cleaner.