Windshield: Service and Repair
SPECIAL TOOL(S)
REMOVAL
All vehicles
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING GLASS FROM THE VEHICLE.
1. Remove the RH and LH windshield side garnish mouldings.
^ If equipped with a convertible top, remove the pin-type retainers.
2. Remove the interior rear view mirror.
Convertible
3. Remove the visor trim moulding.
4. Remove the screws and the sun visors.
^ Disconnect the electrical connector(s).
5. Remove the weatherstrips.
6. Remove the screws and the weatherstrip retainers.
7. Remove the screw and the exterior A-pillar moulding.
Coupe
8. Remove the sun visors and clips
^ Remove the screws.
^ Remove the clips.
9. Remove the roof side trim moulding.
10. Lower the front portion of the headliner.
All vehicles
11. Remove the two windshield wiper pivot arms.
1 Raise up on the pivot arms.
2 Release the retainer tabs, and release the windshield wiper pivot arms.
12. Remove the cowl grille weatherstrip.
13. Remove the cowl grille.
14. Using a soft brush or vacuum, clean any dirt or foreign material from the pinch weld.
15. Using the special tool, starting at the top center of the windshield cut the urethane adhesive from the windshield glass and work down the sides.
CAUTION:
^ Cover the instrument panel to prevent possible damage.
^ Care must be taken to prevent scratching the pinch weld.
NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting.
16. Using the special tool, distance the windshield glass from the body.
17. Using the special tool cut the urethane adhesive and remove the windshield.
18. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
INSTALLATION
All vehicles
CAUTION: After installing the urethane installed windshield, 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 ESSEX drive away chart for cure times as temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond.
1. Dry-fit the windshield glass by centering it side-to-side and by adjusting the setting blocks (if equipped) to get the correct position of the part top-to-bottom. Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body
2. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane is removed leaving a level bead around the entire pinch weld.
CAUTION: Care must be taken to avoid scratching the pinch weld.
3. Using a wool applicator, apply the 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.
4. If reinstalling the original windshield glass, remove the excess urethane adhesive from the windshield glass.
5. If installing a new windshield glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
6. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the class surface to be prepped.
CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area.
7. If installing a new windshield glass, apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was in the previous step. Allow five minutes to dry.
8. Cut the applicator tip to specification.
9. Apply a bead of Urethane Adhesive Essex 400-HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld.
CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, Urethane Adhesive Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time.
10. Using the alignment marks install the windshield glass.
CAUTION: Open a window to prevent the windshield glass from being pushed out by air pressure when a door is closed.
11. After the glass is set, check for water leaks and add urethane adhesive where needed.
12. Install the cowl grille.
13. Install the cowl grille weatherstrip.
14. Install the two windshield wiper pivot arms.
^ Position the arms.
^ Install the windshield wiper pivot arms.
15. Install the headliner.
Coupe
16. Install the sun visors and clips.
17. Install the roof side trim moulding.
Convertible
18. Install the exterior A-pillar moulding and screw.
19. Install the weatherstrip retainers.
20. Install the weatherstrips.
21. Position the sun visors and install the screws.
^ Connect the electrical connector(s).
22. Install the visor trim moulding.
All vehicles
23. Install the RH and LH windshield side garnish moulding.
^ If equipped with a convertible top, install the pin-type retainers.
24. Install the interior rear view mirror.