Windshield: 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 interior rear view mirror.







2. Remove the instrument defroster opening grille assembly.
^ Disconnect the electrical connector.







3. Remove the RH and LH windshield side garnish mouldings.







4. Remove the sun visor and clips.
1 Remove the screws.
2 Remove the visor.
^ Disconnect the electrical connector.

3 Remove the clips.

5. If equipped, remove the overhead console.
6. Lower the front portion of the headliner.
7. Remove the cowl grille.
8. Using a soft brush or vacuum, remove any dirt or foreign materials from the pinch weld.







9. Using the special tool, start at the top center of the windshield and cut the adhesive away form the glass working down the sides.

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

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







10. Using the special tool, distance the windshield glass from the body.







11. Using the special tool, cut the remaining adhesive and remove the windshield glass.
12. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

INSTALLATION

CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary.) Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive 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 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 adhesive on the pinch weld using the full-cut method. Leave a level bead around the entire pinch weld.

CAUTION: Care must be taken not to scratch the pinch weld.

3. Use the wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to ten minutes to dry.







4. Install Norton Foam Sealant 565 Black Foam Tape meeting Ford specification ESB-M3G77A to the pinch weld.
5. If reinstalling original windshield glass, remove the excess urethane adhesive 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. If installing a new windshield 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 using deliberate strokes, making sure not to overlap the applied area.

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







9. Cut the urethane adhesive applicator tip to specification.







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

CAUTION: If 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 one hour cure time.
11. 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.

12. After the glass is set, check for water leaks and add urethane adhesive where needed.
13. Install the cowl grille.
14. Install the front portion of the headliner.
15. If equipped, install the overhead console.







16. Install the LH and RH windshield side garnish mouldings.







17. Install the instrument defroster opening grille assembly.
^ Connect the electrical connector.







18. Install the sunvisors and clips.
1 Install the clips.
2 Connect the electrical connector.
3 Install the screws.

19. Install the rear view mirror.