Windshield: Service and Repair
REMOVAL
1. Remove door weatherstrips, weatherstrip retainers and front roof trim panel.
WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT PERSONAL INJURY.
2. Remove windshield wipers.
3. Remove cowl weatherstrip and cowl vent screen.
4. Remove inside rear view mirror.
5. Remove sun visors and visor retainers.
6. Drop headliner down near windshield opening to avoid cutting headliner during windshield removal. Place a small block of suitable material between headliner and roof to act as spacer.
Rotunda Interior Auto Glass Cut-Out Knife Kit:
7. Use Rotunda Knife With Offset Blade 107-R1511, Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalents to cut adhesive. Refer to manufacturer's instructions when using tool.
CAUTION: Use care to avoid damage to the instrument panel.
NOTE: Spray area to be cut with water to make cutting operation cooler and easier.
8. Remove windshield and moulding assemblies from vehicle using suitable suction tool.
9. Trim remaining urethane on pinch weld to within 1 and 1.5 mm (0.04 and 0.06 inch) thickness with utility knife or razor blade. Clean and dry urethane. When completed, surface should be smooth and free of cuts and contamination.
10. Check pinch weld sealing area for damaged sheet metal, rust or foreign objects which may have caused, or may cause, glass breakage. Service metal if necessary.
INSTALLATION
1. If painted sheet metal has been exposed anywhere along the flange, use the supplied wool applicator and apply Urethane Metal Primer or equivalent meeting Ford specification WSB-M2G234-C to windshield pinch weld.
NOTE: A minimum of 10 minutes is required for primer surface to dry.
2. Place windshield and moulding assembly on a low, stable work surface, inside up.
3. Clean windshield with non-alcohol-based glass cleaner.
4. Using a clean wool applicator, wipe inside glass edge with Urethane Glass Prep or equivalent meeting Ford specification WSB-M5B280-C2, 25 mm (1 inch) wide along top, sides and bottom. Wipe off glass prep and repeat application.
NOTE: Wipe off Urethane Glass Prep or equivalent meeting Ford specification WSB-M5B280-C2 immediately after application because it flash dries. Prep application must be applied twice.
5. Properly align windshield glass to body.
a. Place windshield glass into opening. Center it top and bottom, side-to-side (adjust lower glass stops if necessary).
b. Using masking tape or crayon, make alignment marks at points on four sides of both glass and window opening.
6. Remove windshield glass from vehicle and place it back on work table.
7. Thoroughly shake and stir Urethane Glass Primer or equivalent meeting Ford specification WSB-M2G314-B to make sure of uniform pigment mixing.
8. Using a clean wool applicator, apply primer to inside glass edge 25 mm (1 inch) wide along top, sides and bottom.
NOTE: Allow a minimum of five minutes for glass primer to dry.
9. Install foam tape meeting Ford specification ESB-M3G137-A or equivalent along top edge of cowl pinch weld.
10. Apply an even bead of urethane meeting Ford specification WSB-M2G316-B around entire sheet metal pinch weld on top of existing bead of urethane. The bead should be triangular in shape, 16 mm (0.625 inch) high and 8 mm (0.33 inch) at base.
NOTE:
^ Leave a door window slightly open until adhesive is cured.
^ Apply new urethane on top of existing material on pinch weld.
11. Install windshield assembly onto vehicle, taking care to align marks on glass to marks on body. This must be done before adhesive skins over.
12. Remove spacer from headliner and install sun visors and retainers.
13. Install inside rear view mirror.
14. Install cowl vent screen and cowl weatherstrip.
15. Install windshield wipers.
16. Install roof trim panel, A-pillar trim panel and door weatherstrip.
17. Check installation for air and water leaks in urethane seal.
CAUTION:
^ Use only urethane for service of air and water leaks in urethane set windshield.
^ When replacing urethane installed glass parts, do not drive the vehicle until the urethane has cured. At temperatures above 13°C (55°F) and relative humidities above 50%, adequate cure time is typically 12 to 24 hours (less at higher temperatures and lower humidities). See detailed instructions provided by the urethane manufacturer. Inadequate or improper curing may adversely affect the retention of the windshield.