Mercury Grand Marquis Formal Coach Roof

NOTE: The procedure for replacing the roof outside cover is outlined in Section 46-20 of the Car Shop Manual. The procedure that follows is for removal and installation of the cover and cap assembly and/or the backlite glass.

1. Remove the backlite garnish moulding, headliner and exterior ornamentation and mouldings as outlined in Section 46-20 of the Car Shop Manual under Roof Outside Cover.

2. Using a rounded putty knife or other suitable tool, loosen the silicone seal around the backlite opening.

3. Peel back the vinyl and padding all around the top far enough for access to the pop rivets retaining the cap assembly.

4. Drill out all of the cap pop rivets. If the cap is to be replaced, lift it off the vehicle. If the back glass is to be replaced prop the cap approximately 6 inches above the backglass extension assembly and proceed with the following steps.

5. Disconnect the heated backlite wires.
6. Remove the 5 backlite to backlite extension retainers by drilling out the pop rivets with a 1/8" drill bit.

7. Replace the backlite glass as outlined in the Car Shop Manual in Section 43-11-Glass, StationaryButyl Type Seal.

8. Install the backlite glass retainers using 1/8" x .328 pop rivets.

9. Connect the heated backlite wires.

10. Apply zinc rich primer to all drilled rivet holes in the sheet metal.

11. Position the cap assembly to the body and rivet in place using 1/8" x .328 flat head rivets.

12. Using Ford Vinyl Roof Adhesive (D9AZ-19C525-A) or equivalent, secure the padding and vinyl as required.

13. Reinstall exterior and interior trim as outlined in Section 46-20 of the Car Shop Manual.

14. Apply a bead of silicone rubber sealer around the backlite opening using Ford D6AZ-19562-A (clear) D6AZ-19562-B (black) or equivalent.