Windshield Glass

REMOVAL
These are the tools recommended to properly remove and install the windshield:
- Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450, or equivalent.
- Razor Blade Knife.
- Shop Towels.
- Installation kit E0AZ-19562-A or equivalent.
- Alcohol-free glass cleaner in a spray bottle.

1. Remove the windshield wiper pivot arms.
2. Remove the cowl top vent grille.







3. Remove the six windshield glass stop bolts. Remove the windshield glass stop.
4. Remove the roof side inner front mouldings.
5. Grasp the inside rear view mirror firmly.
6. Unscrew the inside rear view mirror Allen screw and remove the inside rear view mirror and its mount.
7. Remove the two inside visor screws from the inside visor brackets.
8. If equipped, disconnect the vanity mirror lamp electrical connector.
9. Remove the inside visors.
10. Remove the map lamp housing.
11. Lower the roof headlining enough to keep it out of the way when cutting out the windshield glass.







12. Apply a protective strip of masking tape along the front edge of the roof headlining.
13. Lubricate the urethane sealant holding the windshield glass with water to aid the Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent when cutting out the windshield glass.







14. Use Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent to cut out the windshield glass. Carefully insert the blade into the urethane. Slowly work around the windshield glass.

WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE.

15. Gently push the windshield glass outward 12.7 mm (0.5 inch) from the inside of the vehicle to ensure that the urethane seal is broken.







16. Use a razor blade knife to cut any remaining urethane that is still holding the windshield glass.
17. Remove the windshield glass from the vehicle.







18. 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.
19. 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.
20. 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.
21. If the windshield glass is to be reused, remove the upper windshield moulding protector.
22. If the windshield glass is to be reused, use a razor blade knife to remove the old urethane from the windshield glass.

INSTALLATION
1. Set the windshield glass onto the body and mark the clearance between the top of the windshield glass and the body to 8 mm (0.31 inch) by moving the windshield glass spacers up or down.
2. Remove the windshield glass from the body.
3. Clean the inside of the windshield glass thoroughly with an alcohol-free cleaner.

NOTE: Keep the windshield glass and body surfaces free of dirt, water, and oil.







4. Apply Urethane Glass Prep (part of E0AZ-19562-A), or equivalent meeting Ford specification WSB-M2G234-C, leaving a visible wet streak, in a 15 mm (0.6 inch) wide application around the entire outer edge of the inside of the windshield glass.

NOTE: Wipe off the Urethane Glass Prep (part of E0AZ-19562-A), or equivalent meeting Ford specification WSB-M2G234-C, immediately after application because it flash dries. The Urethane Glass Prep must be applied twice.

5. Immediately wipe the Prep off of the windshield glass with a clean cloth.
6. Repeat this application of the Urethane Glass Prep (part of E0AZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C to the entire outer edge of the glass.
7. Immediately wipe off the primer with a clean cloth.







8. Use the supplied wool applicator to apply Urethane Glass Primer (part of E0AZ-19562-A) or equivalent meeting Ford specification WSB-M2G314-B in a 15 mm (0.6 inch) wide application around the entire outer edge of the inside of the windshield glass. Allow 10 minutes drying time.

WARNING: IF PRIMER GETS ON YOUR HANDS, REMOVE IT IMMEDIATELY.

CAUTION: Do not apply the glass primer inside of the blackout ceramic coating. The primer will permanently discolor the windshield glass.







9. Install open cell Vinyl Foam Tape C6AZ-19627-A, or equivalent meeting Ford specification ESB-M3G77-A to the pinch weld. Start the tape at the bottom center of the pinch weld and place it around the entire edge, 8 mm (0.750 inch) from the inside edge. Cut the tape and butt the ends together.







10. Cut the nozzle of the urethane sealant canister so that it lays a bead of sealant 16 mm (0.625 inch) high and 8 mm (0.310 inch) wide.







11. Starting at the bottom center of the pinch weld, lay a triangular bead of Urethane Sealant (part of E0AZ-19562-A) or equivalent meeting Ford specifications WS8-M2G316-B along the entire outside edge of the open cell foam tape 16 mm (0.625 inch) in height and 8 mm (0.310 inch) wide. Ensure that the continuous bead of urethane sealant is smooth and even. If necessary, reshape the bead with a suitable tool.

12. Lift the windshield glass into position as previously marked, and push it lightly to compress the urethane.

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

13. Clean any excess urethane sealant from the windshield glass or windshield opening flange.







14. Align the upper windshield moulding and push it into place.

CAUTION: The upper windshield moulding must be installed before the sealant has hardened.

15. 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 cure 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 sealant bond.

16. Install the windshield glass stop. Install the windshield glass stop bolts.
17. Install the cowl top vent grille.
18. Install the windshield wiper pivot arms.
19. Install the roof side inner front mouldings.
20. Install the inside visors on the inside visor brackets. Install the inside visor screws and tighten securely.
21. If equipped, connect the vanity mirror lamp electrical connector.
22. Connect the battery ground cable.
23. Install the map lamp housing.
24. If necessary, install the inside rear view mirror mount.
25. Install the inside rear view mirror.
26. Install the inside rear view mirror Allen screw and tighten securely.