Windshield: 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: The vehicle must remain inside until the windshield adhesive has cured.
1. If installed, remove the removable top or lower the convertible top.
2. Remove the interior rear view mirror.
3. Remove the windshield side garnish mouldings.
4. Remove the sun visors and clips.
5. Remove the windshield exterior trim.
6. Remove the cowl vent screen.
7. Disconnect the audio antenna snap connector.
8. Remove the instrument panel defroster opening grille assembly.
^ Disconnect the electrical connectors.
9. Disconnect the two heated wiper park grid electrical connectors.
^ Release the wiring harness locators.
10. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld.
11. Using the special tool, starting at the top center of the windshield glass, cut the urethane adhesive away from the glass and work down the sides.
CAUTION:
^ Cover the instrument panel in order to prevent possible damage.
^ Care must be used to avoid scratching the pinch weld.
NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting.
12. Remove the windshield glass assembly using a suitable suction tool.
13. Remove the dual lock windshield glass stops from the sheet metal frame.
14. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld.
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 windshield glass to the existing urethane bed on the adhesive area. Align the windshield in the opening for uniform fit.
2. Use tape or non-permanent marking pencil to make alignment marks on the windshield and the body to aid in the installation alignment of the new windshield.
3. After alignment, remove the windshield glass from the vehicle and place on a stable work surface.
4. Trim the remaining urethane adhesive on the pinch weld. 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 pinch weld.
5. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair the surface as necessary.
CAUTION: All rust found on the pinch weld must be removed and the pinch weld restored to factory specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an factory recommended curing automotive paint primer and allow to cure thoroughly. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal before proceeding.
6. Use the wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry.
7. Install new the dual lock windshield glass stops.
8. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
9. 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. 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. Install the windshield glass on the vehicle, aligning it with marks made previously.
NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
13. Check the windshield installation for air or water leaks through the urethane bead.
14. Place two strips of tape onto the windshield glass and secure it to the top of the windshield frame. This will help avoid misalignment while the urethane cures.
15. Connect the two heated wiper park grid electrical connectors.
16. Install the instrument panel defrost opening grille assembly.
^ Connect the electrical connector.
17. Connect the audio antenna snap connector.
18. Install the windshield side garnish mouldings.
19. Install the sun visor clips and screws.
20. Install the rear view mirror.
21. Install the exterior windshield mouldings.
22. Install the cowl vent screen.