Windshield: Service and Repair

SPECIAL TOOL(S)

REMOVAL
1. Remove the windshield wiper arms and the blades.

WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT PERSONAL INJURY.

2. Remove the cowl vent screens.
3. Remove the inside rear view mirror.
4. Remove the visors and drop the headliner near the windshield to avoid damaging the headliner. Place a small block of suitable material between the headliner and the roof. Remove the interior garnish mouldings if necessary.







5. Use the Knife with Offset Blade to cut the adhesive.

CAUTION: Use care to avoid damage to the instrument panel.







6. Remove the windshield and moulding assemblies from the vehicle using a suitable tool.

NOTE: Retain the Velcro(R) stops for installation on the new windshield if necessary.







7. Trim the remaining urethane on the pinch weld to within 1.0 to 2.0 mm (0.04 to 0.08 inch) thickness. After completion, the surface should be smooth and free of cuts and contamination.
8. Check the pinch weld sealing area for damaged sheet metal, rust or foreign objects which may cause glass breakage. Repair the metal, if necessary.

INSTALLATION
1. Apply Urethane Metal Primer ESB-M26234-C or equivalent to any exposed metal on the pinch weld.

NOTE: A minimum of 10 minutes is required for the primer surface to dry.







2. Apply Foam Tape along the top edge of the cowl pinch weld.

3. Clean the windshield glass with Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA or an equivalent meeting Ford specification ESR-M14P5-A.

NOTE: Place the windshield glass inside-up on a low stable work surface.

4. Apply the Urethane Glass Prep WSB-M5B280-C or equivalent to the windshield glass inside edges.
^ Wipe the windshield where the Urethane Glass Prep has been applied.

NOTE:
^ Wipe the Urethane Glass Prep off immediately after application because it flash dries. Two coats of the urethane glass prep must be applied.
^ Use a clean wool applicator to apply the Urethane Class Prep.







5. Install the windshield glass stops.







6. Align the windshield glass to the body.
1. Place the windshield glass to the body.
2. Center the windshield glass in the opening.
3. Adjust the windshield stops.
4. Mark the windshield glass alignment on the glass and on the body.

7. Apply the Urethane Glass Primer to the inside edges of the windshield glass.

NOTE:
^ Remove the windshield glass and the moulding assemblies from the vehicle and place them on a work table.
^ The Urethane Glass Primer must be thoroughly mixed for even pigmentation.
^ The Urethane Glass Primer must cure for a minimum of five minutes before the windshield glass can be installed.







8. Apply the new Urethane Adhesive WSB-M2G316-B or equivalent in an even bead Onto the existing urethane on the pinch weld. The applied bead should be approximately 8 mm (0.3 inch) at the base and 14 mm (0.55 inch) high and triangular in shape.

NOTE: The windshield glass must be installed before the Urethane Adhesive skins over.







9. Install the windshield glass on the pinch weld. Align the windshield glass to the body using the alignment marks.

NOTE: Leave a door open slightly until the Urethane Adhesive has cured.

10. Install the windshield moulding assemblies.
11. Install the headliner.
12. Install the inside rear view mirror.
13. Install the cowl vent screens.
14. Install the windshield wiper arms and blades.
15. Inspect the windshield glass for air or water leaks through the urethane seal.