Rear Window Glass - Vehicles With: 4-Door

Removal

1. Refer to: Headliner - Vehicles With: 4-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Refer to: Parcel Shelf (501-05 Interior 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 rear 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 rear window glass starting at the top center and working toward the bottom corners.
   Special Tool(s) : 300-AST1770E Deluxe Air Knife
   General Equipment : Glass Removal Suction Cup

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

Installation

1. Use a non-staining grease pencil to make alignment marks on the rear window glass at the setting blocks (if equipped) and the body to aid in the rear 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. General Equipment: Vacuum.
     

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

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

1. • Dry fit the rear window glass to the existing urethane adhesive bead on the body pinch weld, centering the rear window glass in the opening. Adjust the rear 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 rear window glass stop blocks if equipped) on the rear window glass and the body.
     General Equipment : Glass Removal Suction Cup

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

1. Clean the inside of the new rear 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 rear 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: Position the rear window 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 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 rear 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 rear window glass, open the vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.

   • Install the rear 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.

     Use tape to secure the rear quarter 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 rear 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 rear window glass.
   Material : Motorcraft® Ultra-Clear Spray Glass Cleaner / ZC-23 (ESR-M14P5-A)

1. On both sides.
   

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

1. Refer to: Headliner - Vehicles With: 4-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

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