Method I

CAUTION: 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 this procedure:

Inoperative grid wires on heated rear windows should be serviced by using Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A.

NOTE: If the first layer of the rear window grid (brown color) is damaged or missing it will be necessary to apply Brown Lacquer Touch-Up Paint AL81-5477-B or equivalent on the glass prior to applying the Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A.

NOTE: There are two methods for repairing terminal separation from back window glass and/or grid breaks. Method one involves soldering the terminal to the glass and method two uses an epoxy adhesive.

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

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

Mixing
Rear Window Defroster Repair D8AZ-19562-AA or equivalent meeting Ford specification ESB-M4J58-A and touch-up paint, if needed, must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use.

Application
1. Mark the location of the break on the outside of the window.







2. Using cellulose tape, mask off the area directly above and below the grid break. The break area should be at the center of the mask and the tape gap must be no wider than the existing grid line.
3. Apply the service coating in several smooth continuous strokes (allowing 3-5 minutes drying time between coats) across the break areas using the brush applicator in the cap. Extend the service coating at least 6 mm (1/4 inch) on both sides of the break area.

NOTE: If both brown and silver layers of the grid are broken or missing, apply a coat of the brown touch-up paint across the break area first. Two coats may be necessary to obtain the proper color. Allow the touch-up paint to dry, then apply three coats of silver grid repair compound, allowing three to five minutes drying time between coats. The coating of the silver grid repair compound should extend at least 6 mm (1/4 inch) on each side of the break area.

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

CAUTION: In this procedure, be careful not to damage the grid line with the razor blade.

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