Removal and Replacement
REMOVALThese are the tools recommended to properly remove and install the back window glass:
- Rotunda Interior Auto Glass Cut-Out Knife kit 164-R2450, or equivalent.
- Razor Blade Knife.
- Shop Towels.
- Installation Kit E0AZ-19562-A.
- Alcohol-free glass cleaner in a spray bottle.
1. Remove the luggage compartment cover.
2. Remove the liftgate upper moulding, liftgate side mouldings and liftgate door trim panel.
3. Remove the rear hi-mount lamp.
4. If equipped, disconnect the heated back window switch and light electrical connectors.
5. Remove the two spacers at the top of the back window glass.
6. Remove the two spacers at the bottom of the back window glass.
7. Lubricate the urethane sealant with water to aid the Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent when cutting out the back window glass.
8. Use Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent to cut out the back window glass. Carefully insert the blade into the urethane at the top center of the back window glass. Slowly work around the back window glass.
CAUTION: Do not damage the back window glass mouldings when cutting the urethane. The back window glass mouldings cannot be replaced separately from the back window glass.
9. Gently push the back window glass outward 12.7 mm (0.5 inch) from the inside of the vehicle to ensure that the urethane seal is broken.
10. Use a razor blade knife to cut any remaining urethane that is still holding the back window glass.
11. Remove the back window glass from the vehicle.
12. Trim the remaining old urethane on the pinch weld to within 1.0-2.0 mm (0.04-0.06 inch) thickness using a suitable tool. When completed, the old urethane surface should be smooth and free of cuts and contamination.
13. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material which may cause glass damage. Service the pinch weld sheet metal as necessary.
14. Using the supplied wool applicator, apply Urethane Metal Primer (part of E0AZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld flange. Allow 10 minutes drying time for the primer.
15. If the back window glass is to be reused, use a razor blade knife to remove the old urethane from the back window glass.
CAUTION: Do not remove the locating pins when removing the old urethane from the back window glass.
INSTALLATION
1. Clean the inside of the back window glass thoroughly with an alcohol-free glass cleaner.
NOTE: Keep the back window glass and body surfaces free of dirt, water, and oil.
2. Apply Urethane Glass Prep (part of E0AZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C, leaving a visible wet streak, in a 25 mm (1 inch) wide application around the entire outer edge of the glass, directly inside the moulding.
3. Immediately wipe the Prep off the back window glass with a clean cloth.
4. Repeat this application of the Urethane Glass Prep (part of E0AZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C to the entire edge of the back window glass.
5. Apply Urethane Glass Primer (part of E0AZ-19562-A) or equivalent meeting Ford specification WSB-M2G314-B in a 25 mm (1 inch) wide application around the entire outer edge of the inside of the back window glass. Allow 10 minutes drying time.
WARNING: IF PRIMER GETS ON YOUR HANDS, REMOVE IT IMMEDIATELY.
6. Install Open Cell Vinyl Foam Tape C6AZ-19627-A or equivalent meeting Ford specification ESB-M3G77-A, to the pinch weld area. Start the foam dam at the center of the bottom pinch weld and lay it around the entire pinch weld 8 mm (3/8 inch) from the inside edge.
7. Cut the nozzle of the urethane canister so that it lays a triangular bead of sealant 16 mm (0.625 inch) high and 5 mm (0.310 inch) wide.
8. Starting at the bottom center of the pinch weld, lay a uniform bead of Urethane Sealant (part of E0AZ-19562-A) or equivalent meeting Ford specification WSB-M2G316-B along the entire outside edge of the foam dam 16 mm (0.625 inch) in height and 8 mm (0.310 inch) wide. Ensure that the bead of urethane sealant is smooth and even. If necessary, reshape the bead with a suitable tool, taking care not to trap air in the bead.
9. Install the four spacers.
10. Open the front door window glass to prevent the back window glass from being pushed out by air pressure if a front door is closed.
11. Align the locating pin and lift the back window glass into position. Push in lightly on the back window glass to compress the urethane.
12. Clean any excess urethane sealant from the back window glass or flange.
13. After the urethane sealant has cured, check for water leaks. If a leak is found, dry the area completely and add urethane sealant where needed.
CAUTION:
- Use only Urethane (part of E0AZ-19562-A), or equivalent meeting Ford specification WSB-M2G316-B to service water and air leaks of the urethane sealant.
- After replacing the urethane installed glass the vehicle should not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% curing time is 12-24 hours (decreasing at higher temperatures and lower humidities). Refer to the detailed instructions provided by the manufacturer in the kit. Inadequate curing of the urethane may adversely affect the strength of the urethane bond.
14. If equipped, connect the heated back window switch and light electrical connectors.
15. Install the rear hi-mount lamp.
16. Install the liftgate upper moulding, liftgate side mouldings, and liftgate door trim panel.
17. Install the luggage compartment cover.
18. After the urethane sealant has properly cured, check the back window glass for water leaks. If a leak is found, dry the area completely and add urethane where needed.
CAUTION: Allow all back window glass parts installed with urethane ample time to cure.
NOTE: Use only urethane to after-seal all air and water leaks.