Back Window Glass: Service and Repair

REAR WINDOW GLASS

Special Tool(s):

SPECIAL 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 high mounted stoplamp.







2. Disconnect the LH and RH rear window defroster grid electrical connectors.
3. Lower the headliner near the back window glass and support it with a suitable support.
4. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.







5. NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting the urethane adhesive.

Using the special tool, place the flat side of the knife against the back window glass. Start at the top center and work out and down the pillars to the lower corners.







6. Install the special tool into the top of the back window glass and inflate. Cut from corner to corner along the bottom of back window glass.
7. Remove the back window glass.
8. 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. Adequate cure time is specified on the drive away chart for each urethane product as the temperature and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the back window glass.

NOTE: On Taurus vehicles only, allow for a 5mm gap between roof, body sides and the back window glass.

1. Dry fit the back window glass to the existing urethane adhesive on the body pinch weld. Align the glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks to aid in the installation alignment of the back window glass.
3. Remove the back window glass.







4. NOTE: Avoid scratching the pinch weld area. A portion of the pinch weld will be visible once the rear window glass is installed.

Trim the urethane adhesive on the pinch weld. The urethane adhesive must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane adhesive surface after preparation.

5. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primers. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure.

Apply urethane metal primer to any exposed or damaged metal on the pinch weld.

6. If installing the original back window glass, remove the excess urethane adhesive.
7. Clean the back window glass with a non-alcohol based window cleaner.

8. CAUTION:
- Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure.
- Wipe off the urethane glass prep immediately after each application because it flash dries.

If installing a new back window glass, and if using a 2-part prep and primer, apply urethane glass prep twice to the area to be urethaned.

9. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure.

NOTE: Sika uses the same black primer for the glass and pinch weld area.

If installing a new back window glass, apply urethane glass primer to the area where urethane will contact the glass. Allow 5 minutes to dry.







10. Cut the urethane adhesive applicator tip to specification.







11. CAUTION: Select the urethane adhesive with the appropriate curing time that will ensure the adhesive is cured before vehicle is driven.

NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and continuous bead.

Apply urethane adhesive on top of the existing urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the back window glass near the center.







12. NOTE: On Sable vehicles only, adjust the back window glass on the setting blocks.

Install the back window glass on the pinch weld. Align the back window glass to the body using the alignment marks.

13. CAUTION: Carry out this step after the urethane has cured.

Check the back window glass for air or water leaks through the urethane adhesive seal.

14. Install the headliner.







15. Connect the LH and RH rear window defroster connectors.
16. Install the high mounted stoplamp.