Windshield: Service and Repair

WINDSHIELD GLASS

Special Tool(s):

Special tool(s)

Material:

Material

WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting and removing the glass from the vehicle.

1. Remove the A-pillar trim panels, sun visors and retainers and the overhead console.
2. Remove the interior mirror.
3. Lower the front portion of the headliner.
4. Remove the cowl panel grille.
5. Remove the components in the order indicated in the illustration and table.







6. To install, reverse the removal procedure.

Item 1: Windshield Glass Removal Note

NOTE:
- Lubricate the urethane adhesive with water to aid the special tool when cutting.
- Removing the windshield glass requires more than one technician.
- Be sure not to scratch the pinch weld when removing the windshield glass.







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







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







3. Using the special tool, cut the remaining urethane adhesive.
4. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.

Item 2: Moulding Assembly Removal Note
1. Be sure not to scratch the pinch weld when removing the windshield glass.

Item 2: Moulding Assembly Installation Note
1. The moulding must be installed on the windshield glass before installing the windshield in the vehicle.

Item 1: Windshield Glass Installation Note

1. CAUTION:
- Do not drive the vehicle after installing windshield glass until the urethane sealant has cured. Inadequate curing of the urethane sealant adversely affects the strength of the urethane sealant bond.
- If using Essex 400 urethane sealant, 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 higher humidities.
- Do not scratch the pinch weld area.
- Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed.

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

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







3. Use the wool applicator to apply urethane metal primer Essex U-413 or equivalent, meeting Ford specification WSB-M2G3 14-B, to any exposed metal on the pinch weld. Allow six to ten minutes to dry.

4. NOTE:
- If reinstalling the original windshield, remove excess urethane adhesive from the windshield glass.
- If installing a new windshield, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
- Wipe off the glass prep immediately after each application.

Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M5B280-C twice around the glass surface to be urethaned.

5. Apply Urethane Glass Prep Essex U-402 meeting Ford specification WSB-M2G314-B to the same area that was prepared in the previous step. Allow five minutes to dry.

6. Cut the urethane applicator tip to specification.






7. Apply a bead of Urethane Adhesive Essex 400-HV meeting Ford specification WSB-M2G316-B, to the pinch weld just outside the foam dam.






8. Install the windshield glass by aligning it to the marks previously made.

9. After the windshield glass has set, check for water leaks and add urethane adhesive where needed.