Back Window Glass: Service and Repair
SPECIAL TOOL(S)
REMOVAL
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING THE HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE.
NOTE: For the removal and installation of the convertible top rear window glass, refer to Convertible Top.
1. Remove the removable top from the vehicle.
2. Remove the package tray from the removable top.
3. Position the headliner aside.
4. Disconnect the two heated grid electrical connectors.
5. Using a soft brush or vacuum, remove dirt and foreign material from the adhesive area.
6. Using the special tool, starting at the top center of the rear window glass, cut the urethane adhesive away from the glass and work down the sides.
CAUTION: Care must be used to avoid scratching the removable top.
NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting.
7. Remove the rear window glass.
8. Using a soft brush or vacuum, remove dirt and foreign material from the adhesive area.
INSTALLATION
CAUTION: After installing the new urethane-installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex driveaway chart for the cure times as the temperatures and humidity vary.) Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond.
1. Dry fit the new rear window glass to the existing urethane bed on the adhesive area. Align the rear window glass in the opening for uniform fit.
2. Use tape or non-permanent marking pencil to make alignment marks on the rear window and the body to aid in the installation of the new rear window glass.
3. After alignment, remove the rear window glass from the vehicle and place on a stable work surface.
4. Trim the remaining urethane adhesive on the adhesive area. The urethane must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.
CAUTION: Care must be taken to avoid scratching the adhesive area.
5. Use the wool applicator to apply Urethane Primer Essex meeting Ford specification WSB-M2G234-C to any exposed material on the urethaned area. Allow 6 to 10 minutes to dry.
6. If re-installing the original rear window glass, trim the remaining urethane adhesive from the rear window glass surface, leaving a thin layer for adhering to the new urethane bead.
7. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
8. Align the "V" notch in the ceramic paint and rear window glass center. Fully seat the rear window glass outside molding along the top edge of the rear window glass and along the sides and bottom edges of the rear window glass.
NOTE: If the moulding is already on the rear window glass, proceed to the next step.
9. If installing a new rear window glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-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 with deliberate strokes, making sure not to overlap the applied area.
10. If installing a new rear window glass, apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the previous step. Allow five minutes to dry.
11. Cut the urethane adhesive applicator tip to specification.
12. Apply a bead of Urethane Adhesive Essex meeting Ford specification WSB-M2G316-B to the urethaned area.
CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, Urethane Adhesive Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one-hour cure time.
13. Install the rear window glass on the vehicle, aligning it with marks made previously.
NOTE: The rear window glass must be positioned within 10 minutes of applying the urethane adhesive.
14. Check the rear window installation for air or water leaks through the urethane bead.
15. Place two strips of tape onto the rear window glass and secure it to the removable top. This will help avoid misalignment while the urethane cures.
16. Connect the two heated grid electrical connectors.
17. Install the headliner.
18. Install the package tray.
19. Install the removable top on the vehicle.