Windshield Glass

Removal

1. Refer to: Interior Rear View Mirror (501-09 Rear View Mirrors, Removal and Installation).
   

1. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   

1. On both sides.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. On both sides.
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. On both sides.
   

1. On both sides.
   

1. On both sides.
   

1. NOTE: Windshield removed for clarity.

   Place two blocks of wood spacing the headliner away from the windshield.
   General Equipment : Wooden Block

1. 

   NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinch weld during glass removal.

   NOTE: Insert the blade into the Deluxe Air Knife 300-AST1770E so the flat side is against the glass. This leaves the entire urethane adhesive bead on the pinch weld and allows a dry fit of the replacement windshield glass.

   NOTE: Lubricate the urethane adhesive with water to aid the Deluxe Air Knife 300-AST1770E when cutting.

   Working from inside the vehicle, cut the urethane adhesive starting at the top center and working toward the bottom corners then across the bottom.
   Special Tool(s) : 300-AST1770E Deluxe Air Knife

1. General Equipment : Glass Removal Suction Cup

Installation

1. If installing the original windshield glass, remove the excess urethane adhesive.
   

1. General Equipment : Glass Removal Suction Cup

1. Use a non-staining grease pencil to make alignment marks on the windshield glass at the setting blocks (if equipped) and the body to aid in the windshield window glass alignment during installation.
   General Equipment : Glass Removal Suction Cup

1. Remove the windshield glass from the body.
   General Equipment : Glass Removal Suction Cup

1. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

   NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.

   NOTE: Touching the adhesive surface impairs the rebonding.

   NOTE: Make sure the mating surfaces are clean and free of foreign material.

1. Using a utility knife, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinch weld.
   

1. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld.
   

1. Position the windshield glass on the body.
   General Equipment : Glass Removal Suction Cup

1. Dry-fit the windshield glass on the existing urethane adhesive bead on the pinch weld.
   General Equipment : Glass Removal Suction Cup

1. Position the windshield glass on the pinch weld, centering the windshield glass in the opening. Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
   

1. Make new alignment marks with tape or non-staining grease pencil (preferably at the windshield glass stop blocks if equipped) on the windshield glass and the body.
   

1. Remove the windshield glass from the body.
   General Equipment : Glass Removal Suction Cup

1. After the dry-fit alignment, remove the glass from the windshield opening and place on a stable work surface with the interior side of the glass facing up.
   General Equipment : Glass Removal Suction Cup

1. Clean the inside of the new windshield glass with glass cleaner.
   Material : Motorcraft® Ultra-Clear Spray Glass Cleaner / ZC-23 (ESR-M14P5-A)

1. NOTE: Use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. For additional information, refer to the Material Chart in this procedure.

   Apply glass primer according to the manufacturer's instructions. Allow at least 6 minutes to dry.
   Material : Dow Urethane One Step Glass Primer / Betaprime™ 5500/5500A/5500SA
   Material : Sika Urethane Metal and Glass Primer / Sika 206 G+P

1. Cut the urethane adhesive applicator tip to specification..
   Material : Betaseal™ Express Dow Urethane Adhesive
   Material : Sika Tack ASAP Urethane Adhesive

1. The new urethane adhesive bead applied must be 14 mm (0.551 in) high and 8 mm (0.314 in) wide.
   Material : Betaseal™ Express Dow Urethane Adhesive
   Material : Sika Tack ASAP Urethane Adhesive

1. NOTE: Position the windshield glass within 10 minutes of applying the urethane adhesive.

   NOTE: Use either a high-ratio air, electric, or battery-operated caulk gun that will apply the urethane adhesive with less effort and a continuous bead.

   Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield near the center, make sure there are no gaps in the bead.
   Special Tool(s) : AST405 ( )
   Material : Betaseal™ Express Dow Urethane Adhesive
   Material : Sika Tack ASAP Urethane Adhesive

1. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

   NOTICE: Before positioning the windshield glass, open the vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.

   NOTICE: The door windows must be left open during the adhesive curing time.

   NOTE: The adhesive strip backings must be removed from the A-pillar mouldings before installing the windshield.

   • Install the windshield glass, aligning it to the marks previously made. Press firmly by hand to ensure a good bond to the A-pillar mouldings.
     General Equipment : Glass Removal Suction Cup
   • Using tape, secure the windshield glass in the correct position until the adhesive has cured.
     

1. After the urethane adhesive has cured, visually check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
   

1. If necessary, remove excess urethane adhesive from the exterior surface of the windshield glass.
   Material : Motorcraft® Ultra-Clear Spray Glass Cleaner / ZC-23 (ESR-M14P5-A)

1. NOTICE: Make sure not to crease the headliner when removing the wood blocks.

   NOTE: Windshield removed for clarity.

   Remove the blocks and position the front portion of the headliner.
   

1. On both sides.
   

1. On both sides.
   

1. On both sides.
   

1. On both sides.
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. On both sides.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Refer to: Interior Rear View Mirror (501-09 Rear View Mirrors, Removal and Installation).
   

1. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   

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