Back Window Glass: Service and Repair

SPECIAL SERVICE 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 package tray trim panel.






2. Disconnect the two rear defrost electrical connectors.







3. Disconnect the FM antenna electrical connector.
4. Lower the rear portion of the headliner.
5. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld.







6. Using the special tool start at the top center of the back window glass, cut the sealant away from the glass and work down the sides.

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

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







7. Using the special tool, distance the back window glass from the body.







8. Using the special tool, cut the remaining urethane sealant and remove the back window glass.
9. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld.


INSTALLATION

CAUTION: After installing the new urethane-installed glass, the vehicle should not be driven until the Urethane Sealant has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the Urethane Sealant may adversely affect the strength of the Urethane Sealant bond.

1. Dry-fit the new part 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 alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body.







2. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane is removed leaving a level bead around the entire pinch weld.

CAUTION: Care must be taken to avoid scratching 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. If reinstalling the original back window glass, remove any excess urethane sealant.
5. If installing a new back window glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area Is clean.

6. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G3 14-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 deliberate strokes, making sure not to overlap the applied area.

7. Apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in previous step. Allow five to minutes to dry.







8. Cut the urethane applicator tip to specification.







9. Apply a bead of Urethane Sealant Essex 400-HV or Essex U-216, meeting Ford specification WSB-M2G3 16-B to the pinch weld.

CAUTION: If vehicle is to be driven within 24 hours of urethane sealant application, Urethane Sealant Essex U-216 meeting Ford specification WSB-M2G3 16-B must be used due to its one hour cure time.

10. Using the alignment marks, install the back window glass.

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

11. After the glass is set, check for water leaks and add urethane sealant where needed.
12. Install the rear portion of the headliner.







13. Connect the FM electrical connector.







14. Connect the two rear defrost electrical connectors.
15. Install the package tray trim panel.