Windshield: Service and Repair

WINDSHIELD GLASS

Special Tool(s):

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 cowl grille.







2. Remove the A-pillar trim panels.
- Remove the bolt covers and bolts.

3. If equipped, remove the overhead console.
4. Remove the interior rear view mirror.







5. Remove the sun visors.
1 Remove the four screws
2 Remove the two sun visor and visor arm clips.
- If equipped, disconnect the electrical connectors.

6. Lower the front portion of the headliner.







7. Remove the windshield side mouldings.
- Pull out starting at the top corner.







8. Remove the upper windshield weatherstrip.
- Pull out starting at the corner.

9. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting the urethane.
10. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.







11. CAUTION: Care must be taken to avoid scratching the pinchweld.

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

Using the special tool, cut the urethane adhesive from the windshield glass.
- Insert the blade into the urethane at the top middle of the glass and work toward the top corners.
- Insert the blade at the top corners and work down each side of the glass toward the bottom.







12. CAUTION: Pump special tool 164-R2459 or equivalent slowly as cowl adhesive is cut to avoid breaking glass.

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







13. NOTE: Removing the windshield glass requires an assistant.

Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.

14. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.

INSTALLATION

CAUTION:
- Do not drive the vehicle after installing windshield glass until the urethane adhesive has cured. Inadequate curing of the urethane adhesive adversely affects the strength of the urethane adhesive bond.
- If using Urethane Adhesive Essex 400, the curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. Curing time decreases at higher temperatures and/or lower humidities.
- If a 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.

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

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

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. If reinstalling the original windshield, remove excess urethane adhesive from the windshield glass.
5. 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.

6. CAUTION: Wipe off Urethane Glass Prep Essex U-401 immediately after each application because it flash dries.

NOTE: Apply with deliberate strokes, making sure not to overlap applied area.

Apply Urethane Glass Prep Essex U-401 or equivalent meeting Ford specification WSB-M2G314-B twice around the glass surface to be prepped.

7. 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.







8. Install the upper windshield weatherstrip.







9. Cut the urethane applicator tip to specification.







10. CAUTION:
- Do not drive the vehicle after installing windshield glass until the urethane adhesive has cured. Inadequate curing of the urethane adhesive adversely affects the strength of the urethane adhesive bond.
- If using Urethane Adhesive Essex 400-HV, the curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. Curing time decreases at higher temperatures and/or lower humidities.
- If a 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.

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 butyl dam over the top of the existing urethane bed.







11. CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed.

Using the alignment marks, install the windshield glass.







12. Install the windshield side mouldings.

NOTE: Be sure the moldings seat completely.

13. Install the headliner.
14. Install the interior rear view mirror.
15. Install the overhead console.







16. Install the A-pillar trim panels.
- Install the bolts and covers.







17. Install the sun visors.
1 Position the sun visors.
2 Install the four screws.
- If equipped, connect the electrical connectors.

18. Install the cowl grille.
19. Run the blower motor on defrost HIGH to check for glass that may have fallen into the defroster vents.