Windshield: Service and Repair
SPECIAL SERVICE 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 cowl grille. Cabin Ventilation Grille
2. Remove the LH and RH A-pillar assist handles.
1 Remove the cover and the screws
2 Remove the assist handles.
3. Remove the windshield side garnish mouldings.
4. Remove the overhead console.
5. Remove the interior rear view mirror. For additional information, refer to Mirrors.
6. Position the two sun visors into the side window position and remove the two inside screws.
7. Position the two sun visors into the stored position.
8. Remove the two sun visors.
1 Remove the four screws
2 Remove the two sun visor and visor arm clips
^ If equipped, disconnect the electrical connectors.
9. Lower the front portion of the headliner.
10. Remove the upper windshield weatherstrip.
11. Remove the LH and RH windshield mouldings.
12. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting the urethane.
13. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.
14. Using the special tool, cut the Urethane Sealant from the windshield glass.
^ Insert the blade into the urethane at the top middle and work toward the bottom corners.
CAUTION: Care must be taken to avoid scratching the pinchweld.
NOTE: Lubricate the Urethane Sealant with water to aid the special tool while cutting.
15. Using the special tool, distance the windshield from the body.
16. Using the special tool, cut the remaining urethane sealant and remove the windshield glass.
NOTE: Removing the windshield glass requires more than one technician.
17. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.
INSTALLATION
CAUTION: After replacing the urethane installed glass, the vehicle should not be driven until the Urethane Sealant has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the Urethane Sealant may adversely affect the strength of the Urethane Sealant bond.
1. Dry-fit the windshield glass by centering it side to side and by adjusting the setting blocks (if equipped) to get the correct position of the part top to bottom. Make the alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body.
2. Trim the remaining Urethane Sealant on the pinch weld to within specification.
^ The old urethane surface should be smooth and free of cuts and contamination.
CAUTION: Care must be taken to avoid scratching the pinchweld.
3. Use the wool applicator to apply Urethane Metal Primer Essex U-413, meeting Ford specification WSB-M2G314-B to any exposed metal on the pinch weld. Allow six to ten minutes to dry.
4. Apply 8 mm Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the pinch weld.
5. If reinstalling the original windshield, remove excess Urethane Sealant from the windshield glass.
6. If installing a new windshield glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
7. Apply Urethane Glass Prep Essex U-401 or equivalent 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 flask dries.
NOTE: Apply with deliberate strokes, making sure not to overlap applied area.
8. 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.
9. Cut the urethane applicator tip to specification.
10. Apply a bead of Urethane Sealant Essex 400 HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld just outside the foam butyl dam.
CAUTION: If a vehicle is to be driven within 24 hours of urethane sealant 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 interior rear view mirror. For additional information, refer to Mirrors.
12. Using the alignment marks, install the windshield glass.
CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed.
13. Install the upper windshield weatherstrip.
14. Paddle the excess Urethane Sealant from the two sides of the windshield glass.
NOTE: Use one continuous stroke when removing the excess Urethane Sealant.
15. If necessary, remove excess Urethane Sealant from the outside surface of the windshield glass.
16. Install the LH and RH windshield mouldings.
17. Install the headliner.
18. Install the overhead console.
19. Install the windshield side garnish mouldings.
20. Install the LH and RH sun visors.
1 Position the sun visors.
2 Install the four screws.
^ If equipped, connect the electrical connectors.
21. Position the LH and RH sun visors to the side window position and install the sun visor inside screws.
22. Install the LH and RH A-pillar assist handles.
1 Position the two A-pillar assist handles.
2 Install the four screws and covers.
23. Install the cowl grille. Cabin Ventilation Grille