Body - Rear Bolt-In Glass Installation/Removal Tips
TSB 05-11-906/13/05
REMOVAL AND INSTALLATION OF REAR BOLT-IN GLASS - SERVICE TIP
FORD:
2001-2005 Explorer Sport Trac, F-150, Ranger
ISSUE
Some 2001-2005 Explorer Sport Trac, Ranger, and F-150 vehicles may require replacement or re-sealing of the bolt-in rear glass. This TSB procedure supplements the Workshop Manual to prevent damage to the glass and body during removal, and leaks after installing glass. The 2006 Workshop Manual will be updated to incorporate these changes.
ACTION
Use only a plastic tool to break the foam core butyl seal when removing the glass. When installing glass use only 5/16" (8 mm) foam core butyl for sealing. Refer to the following Service Procedure.
SERVICE PROCEDURE
GLASS REMOVAL
1. Begin glass removal by following the procedure in the Workshop Manual, up to and including removing the attachment nuts.
NOTE
THE BACK WINDOW GLASS HAS A FOAM CORE BUTYL PLACED ON THE RUBBER SEAL TO PREVENT LEAKS. THIS BUTYL SEAL MUST BE BROKEN TO REMOVE THE GLASS MODULE FROM THE BODY.
NOTE
TO BREAK THE BUTYL SEAL USE ONLY A PLASTIC TOOL, REFERRED TO IN THE AUTOMOTIVE GLASS INDUSTRY AS A "PLASTIC" WINDSHIELD SETTING TOOL (FIGURE 1).
2. Slide the plastic setting tool under the window glass outside rubber seal between the attaching studs at one of the corners, to cut through the foam butyl. At the same time apply light hand pressure to the glass from the inside of the vehicle, pressing outward (Figure 2).
3. Once the glass module begins to separate from the body, continue to apply constant hand pressure from within the vehicle while moving around the perimeter of the glass. This will continue to break the foam core butyl seal. Once the seal is completely broken, the glass module may be removed.
4. Remove any remaining foam butyl from the body and window rubber seal before glass installation.
GLASS INSTALLATION
NOTE
DO NOT USE A "SOLID TYPE" BUTYL OR URETHANE AND ATTEMPT TO ROLL IT TO MAKE IT ROUND, THIS WILL CREATE A LEAK. IT WILL ALSO MAKE THE NEXT GLASS REMOVAL EXTREMELY DIFFICULT.
1. Apply the 5/16" (8 mm) foam core butyl to the rear window glass rubber seal, starting at the bottom middle and working around.
2. Overlap the foam butyl by 1" (25 mm) at the starting/finishing points.
3. Complete the installation by following the procedure in the Workshop Manual.
4. Torque the attaching nuts to:
^ 2001-2003 F-150 27 lb-in (3 N.m)
^ 2004 F-150 Heritage 27 lb-in (3 N.m)
^ 2004-2005 F-150 35 lb-in (4 N.m)
^ Explorer Sport Trac 27 lb-in (3 N.m)
^ Ranger 18 lb-in (2 N.m)
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
70422B30 07
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