Back Window Glass: Service and Repair

SPECIAL TOOL(S)

REMOVAL

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

1. Remove the package tray trim panel.







2. Disconnect the back window glass electrical connectors.
3. Using a soft brush or vacuum, clean any dirt or foreign material from the pinch weld.







4. Using the special tool, starting at the top center of the back window glass cut the adhesive from the glass and work down the sides.

CAUTION: Care must be taken to prevent scratching the pinch weld.

NOTE: Lubricate the existing adhesive with water to aid the special tool while cutting.







5. Using the special tool, distance the back window glass from the body.







6. Using the special tool, cut the remaining adhesive and remove the back window glass.

INSTALLATION

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

1. Dry-fit the back window glass by centering it side-to-side and by adjusting the blocks (if equipped) to get the correct position of the part top-to-bottom. Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body.







2. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane is removed leaving a level bead around the entire pinch weld.

CAUTION: Care must be taken to avoid scratching the pinch weld.

3. Using a wool applicator, apply the Urethane Metal Primer Essex U-413 meeting Ford specification WAB-M234-C to any exposed metal on the pinch weld and allow six to ten minutes to dry.
4. If reinstalling the original back window glass, remove any excess urethane adhesive from the glass.
5. If installing a new back window glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
6. If installing a new back window glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be prepped.

CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area.

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







8. Cut the applicator tip to specification.







9. Apply a bead of Urethane Adhesive Essex 400-HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld.

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

10. Using the alignment marks install the back window glass.

CAUTION: Open a window to prevent the back window glass from being pushed out by air pressure when the door is closed.

11. After the glass is set, check for water leaks and add urethane adhesive where needed.







12. Connect the back window glass electrical connectors.
13. Install the package tray trim panel.