Repair Procedure
ATTACHMENT III
REPAIR PROCEDURE
Replacement of Stationary Glass in
"F" Series Vehicles with Sliding Rear Window Assemblies
INSPECTION
Inspect the two stationary glass components of the sliding rear window assembly for the suspect codes (see Inspection page).
- If both of the stationary glass components are not marked with all three of these CODES, complete the 1864 and release the truck.
- If all three of these CODES ARE FOUND on one or both of the stationary glass components, replace both components according to the enclosed repair instructions.
DEALERS MUST:
INSPECT VEHICLES OF OWNERS WHO WISH TO HAVE DEALERS DETERMINE WHETHER THE GLASS SHOULD BE REPLACED.
CHECK BOTH PIECES OF STATIONARY GLASS FOR THE SUSPECT CODES BEFORE MAKING THE REPAIR.
MUTILATE AND SCRAP ALL STATIONARY GLASS REMOVED FROM OWNERS VEHICLES AS A RESULT OF THIS RECALL SERVICE.
REMOVAL:
NOTE: The technician will need a helper, standing in the bed of the truck, to assist in the removal and the installation of the backlite window assembly.
1. a) From the interior of the vehicle remove the top and bottom trim panels.
b) For "F" series Super Cabs, remove the shoulder belt anchor bolts and both of the left and right quarter trim panels and the eight retaining clips.
2. Pull the weatherstrip from the metal flange (inside cab). Using a helper in the bed of the truck to catch the window assembly, push out the window and the weatherstrip as an assembly from the opening. Clean sealant material on metal flange with cleaning agent E4AZ-19C507-AA or equivalent. (Work in a well ventilated area. Avoid breathing cleaning agent fumes). Note the following warning on the Ford brand cleaning agent:
WARNING
HARMFUL IF SWALLOWED. IRRITATING TO EYES AND SKIN. CONTENTS UNDER PRESSURE.
Contains Isopropyl Alcohol and Morpholine (Alkaline Material). Do not take internally. Use only with adequate ventilation. Avoid contact with eyes and prolonged or repeated skin contact. Do not puncture or incinerate container. Do not expose to heat or store at temperature above 120~F (49~C). If swallowed, drink large quantities of water. Call physician immediately. For eye contact, flush eyes with water for 15 minutes and get medical attention. For skin contact, wash thoroughly with soap and water.
KEEP OUT OF REACH OF CHILDREN
E4AZ-19C507-AA
FIGURE 1:
3. Close the sliding windows and place the window assembly on a flat surface with the window latch in the "down" position.
4. Remove bright mylar clip from weatherstrip assembly (See Attachment 1, Figure 1).
FIGURE 2:
5. Remove bright mylar strip from weatherstrip assembly.
6. Remove the weatherstrip from the glass assembly and clean the sealant material from the gasket and slider windows (cleaning agent E4AZ-19C507A-A or equivalent).
7. Turn window over (sliding window latch in the "UP" position) remove screws from lower and upper aluminum track bar for sliding and stationary glass assemblies (See Attachment 1, Figure 2).
8. Using a hammer and a suitable tool lightly tap the upper aluminum track bar upward. Remove upper aluminum track bar. Remove right side sliding glass assembly, lay sliding assembly on flat surface (See Attachment 1, Figure 2).
9. Remove end cap from right side stationary glass assembly (See Attachment 2).
10. Remove right side stationary glass assembly from lower aluminum track bar.
11. Remove upper and lower vinyl "U" channels from right side stationary glass.
Installation
12. Starting at the division bar, place upper and lower "U" channels on the new stationary glass assembly.
13. Install end cap on the new stationary glass assembly.
14. Apply silicone lubricant (COAZ-19553-AA) or equivalent to the lower "U" channel and bottom of the new stationary glass frame.
WARNING: KEEP SILICONE LUBRICANT OUT OF REACH OF CHILDREN
15. Place new glass and "U" channel assembly in the lower aluminum track bar. Align division bar screw hole with lower track bar screw hole using 1/8 inch drill bit. Install lower screws. DO NOT OVER TORQUE. Install right side sliding glass in lower track and slide to the closed position.
16. Repeat procedure 8 through 15 for left side stationary glass.
17. Apply silicone lubricant (COAZ-19553-AA) to both upper "U" channels.
18. Install upper aluminum track bar. Align division bar screw holes with upper track bar screw holes using 1/8 inch drill bit. If necessary, seat with rubber hammer. Install upper track bar screws. DO NOT OVER torque screws.
19. Apply silicone lubricant COAZ-19553-AA or equivalent to the weatherstrip and track, turn window assembly over (sliding window latch in the "down" position) and install weatherstrip around glass assembly.
20. Install mylar strip on weatherstrip.
21. Install mylar clip. Also install a draw cord around the weatherstrip in the flange crevice, allowing the cord to overlap at the bottom center of the glass. Coat the weatherstrip mounting surface with Rubber Lubricant D9AZ-19583-A or equivalent.
FIGURE 1:
22. Apply liquid butyl sealer C9AZ-19554-B or equivalent to the back window opening (See Attachment 3, Figure 1). Note the following warning on the Ford brand sealer:
WARNING! FLAMMABLE VAPOR HARMFUL IRRITATING TO SKIN AND EYES.
Contains petroleum naphtha. Keep away from heat, sparks or open flame. Use with adequate ventilation. Avoid prolonged contact with skin. If swallowed, do not induce vomiting. Call physician immediately. In case of eye contact, flush eyes with water for 15 minutes and get medical attention. For skin contact, wash with water.
KEEP OUT OF THE REACH OF CHILDREN.
FIGURE 2:
23. Position the glass and weatherstrip to the window opening. With an assistant applying hand pressure from the bed of the truck:
a. Pull the weatherstrip lip over the window opening flange with the draw cord (See Attachment 3, Figure 2).
b. Pull the weatherstrip over the lower flange, pulling one end of the cord at a time.
c. Then pull the weatherstrip seal over the side flanges and upper flange.
24. Replace interior trim panels.
25. Replace shoulder belt anchor bolts. Using a torque wrench, tighten the bolts to 22-32 ft.lbs.
26. Test for water leaks. If leak exists, apply caulk and additional sealer.
27. Clean the glass and the area around the window to remove all excess sealer with cleaning agent E4AZ-19C507A-A or equivalent.
MUTILATE AND SCRAP PROCEDURE
28. Lay the stationary lite with the subject codes on a flat surface.
29. Tape one side of the glass using 4 pieces of tape in the vertical direction and 4 in the horizontal direction.
NOTE: You must wear safety glasses before attempting the next operation.
30. With safety glasses on, place center punch at the lower edge of the glass, strike center punch with hammer. Discard glass.