Windshield: Service and Repair

SPECIAL TOOL(S)

REMOVAL

WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE.







1. Remove the windshield side garnish mouldings.
2. Remove the interior rear view mirror.
3. Remove the overhead console.







4. Remove the sun visors.
1 Remove the sun visor screws.
2 Remove the sun visors.
^ If equipped, disconnect the electrical connector.







5. Remove the sun visor clips.
1 Remove the sun visor clip screws.
2 Remove the sun visor clips.
6. Lower the front portion of the headliner.
7. Remove the cowl grille.







8. Remove the upper windshield weatherstrip.







9. Remove the LH and RH windshield mouldings.
10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.







11. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and work toward the bottom corners.

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







12. Using the special tool, distance the windshield from the body.







13. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
14. Using a soft brush or vacuum, remove any foreign material or dirt 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 Essex Drive Away Chart for cure times, as temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane bond.

1. Dry fit the windshield. Make alignment marks with tape or non-staining grease pencil.







2. Trim the remaining urethane adhesive on the pinch weld to within the specification.
^ The existing urethane adhesive surface should be smooth and free of cuts and contamination.

CAUTION: Do not scratch the pinch weld area.

3. Use a 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. Apply (A) Foam Dam meeting Ford specification WSB-M2G234-C to the (B) pinch weld.
5. If reinstalling original windshield, remove the excess urethane adhesive from the windshield glass.
6. Clean the inside of the glass surface with an alcohol-free cleaner making 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 urethaned.

NOTE: Wipe off the Glass Prep immediately after each application because it flash dries.

8. If installing a new windshield glass, apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the pervious 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, which meets Ford specification WSB-M2G316-B to the pinch weld just outside the foam dam.

CAUTION: If the vehicle is to be driven within 24 hours of urethane application, urethane adhesive Essex U-216 must be used due to its one hour cure time.







11. Install the windshield glass aligning it to the marks previously made.
12. After the windshield glass is set, check for water leaks and add urethane adhesive where needed.







13. Install the upper windshield weatherstrip.
14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass.







15. Install the LH and RH windshield mouldings.
16. Install the Cowl grille.
17. Install the overhead console.







18. Install the sun visor clips.
1 Position the sun visor clips.
2 Install the screws.







19. Install the sun visors.
1 Position the sun visors.
^ If equipped, connect the electrical connector.
2 Install the screws.
20. Install the front portion of the headliner.
21. Install the interior rear view mirror.







22. Install the windshield side garnish mouldings.