Windshield: Service and Repair

SPECIAL SERVICE TOOL(S)

REMOVAL

WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING THE HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE.

1. Remove the cowl grille.
2. Remove the interior rear view mirror. For additional information, refer to Mirrors.







3. Remove the LH and RH windshield side garnish mouldings.







4. Remove the eight screws, the LH and RH sun visors and the two sun visor clips.
5. If equipped, remove the dome lamp assembly. For additional information, refer to Lighting and Horns.
6. Partially drop the headliner near the windshield opening and block with suitable material.
7. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.







8. Using the special tool, place the flat side of the knife against the windshield glass. Start at the top of the windshield glass and work towards the comers.

NOTE: Lubricate the urethane sealant with water to aid the special tool in cutting the urethane.







9. Install the special tool into the top of the windshield glass and inflate. Cut the urethane sealant from corner to comer along the bottom of the windshield glass.
10. Remove the windshield glass.
11. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

INSTALLATION

CAUTION: When installing urethane installed glass parts, the vehicle must not be driven until the urethane has cured. At temperatures above 21°C (70°F) and relative humidities above 50%, adequate cure time is typically 24 hours, (less at higher temperatures and higher humidities). See detailed instructions provided by the urethane manufacturer. Inadequate or incorrect curing can adversely affect the retention of the windshield.

1. Dry fit the windshield glass to the existing urethane sealant 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. Trim the remaining urethane sealant on the bead on the pinch weld. The urethane sealant must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.

NOTE: Avoid scratching the pinch weld.

4. Apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to minor scratches or exposed metal on the pinch weld caused during removal. Do not apply primer to the existing urethane sealant.
5. If installing the original windshield glass, remove the excess urethane sealant.
6. Clean the inside of the windshield glass surface with a non-alcohol based glass cleaner.

7. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M5B314-B to the area to be urethaned.

CAUTION: Wipe off the Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M5B314-B immediately after each application because it flash dries.

8. If installing a new windshield glass, apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area in the previous step. Allow five to seven minutes to dry.







9. Cut the urethane sealant applicator tip to specification.







10. Apply Urethane Sealant Essex U-216 or Essex 400-HV meeting Ford specification WSB-M2G316-B on top of the existing trimmed urethane adhesive head on the pinch weld. Make sure that all gaps in the urethane sealant are smoothed into one continuous bead.

CAUTION: If vehicle is to driven within 24 hours of urethane application, Urethane Sealant Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time.

11. Install the windshield glass on the vehicle aligning it with the markings made previously.
12. Check the windshield installation for air or water leaks through the urethane seal.
13. Position the headliner.
14. If equipped, install the dome lamp assembly. For additional information, refer to Lighting and Horns.







15. Install the two sun visor clips, the LH and RH sun visors, and the eight screws.







16. Install the RH and LH windshield side garnish mouldings.

NOTE: When installing the windshield side garnish mouldings, be sure the alignment tabs are positioned correctly.

17. Install the interior rear view mirror. For additional information, refer to Mirrors.
18. Install the cowl grille.