Liftgate Window Glass - Vehicles With: 5-Door

Removal

1. Refer to: Liftgate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Refer to: Luggage Compartment Lid Moulding - Vehicles With: 5-Door (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Refer to: Rear Spoiler - Vehicles With: 5-Door (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. On both sides.
   

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 liftgate window glass.

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

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

1. Remove the liftgate window glass.
   General Equipment : Glass Removal Suction Cup

Installation

1. Use a non-permanent pencil to make alignment marks on the liftgate window glass at the setting blocks (if equipped) and the liftgate to aid in the liftgate window glass alignment during installation.
   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 rebonding.

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

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

1. If installing the original liftgate window glass, visiually inspect and remove remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive bead.
   

1. Install the liftgate window glass.
   General Equipment : Glass Removal Suction Cup

1. • Dry fit the liftgate window glass to the existing urethane adhesive bead on the body pinch weld, centering the liftgate window glass in the opening. Adjust the liftgate window glass stop blocks (if equipped) as needed for best fit.
     
   • Make new alignment marks with tape or non-staining grease pencil (preferably at the liftgate window glass stop blocks if equipped) on the liftgate window glass and the body.
     General Equipment : Glass Removal Suction Cup

1. Remove the liftgate window glass.
   General Equipment : Glass Removal Suction Cup

1. Clean the inside of the new liftgate window 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.

   If installing a new liftgate window glass, apply glass primer according to 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: The liftgate window glass must be positioned 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 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 liftgate window glass near the center, making 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 liftgate window glass, open the vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.

   • Install the liftgate window glass, aligning it to the marks previously made.
     General Equipment : Glass Removal Suction Cup

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

     Using tape, secure the liftgate window glass in the correct position until the adhesive has cured.
     

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).

   After the urethane adhesive has cured, check the liftgate window 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 liftgate window glass.
   Material : Motorcraft® Ultra-Clear Spray Glass Cleaner / ZC-23 (ESR-M14P5-A)

1. On both sides.
   

1. Torque : 15 Nm

1. Refer to: Luggage Compartment Lid Moulding - Vehicles With: 5-Door (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Refer to: Rear Spoiler - Vehicles With: 5-Door (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Refer to: Liftgate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

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