Windshield Glass: Installation
- Dry-fit the new windshield glass on the existing urethane bead on the pinchweld.
- Position the windshield glass on the pinchweld.
- Center the windshield glass in the opening.
- Adjust the setting blocks as needed for best fit.
- Using tape or non-permanent marker, make alignment marks (preferably at the setting blocks) on the windshield glass and the body.
- After the dry-fit alignment, remove the glass and molding assembly from the windshield opening and place on a stable work surface with the interior side of the glass facing up.
- Using a clean rag, brush or oil-free compressed air, to clean the pinchweld area around the existing urethane. Remove any foreign material or water that may have entered during windshield removal.
- Trim the remaining urethane bead on the pinchweld to specification.
- Check the pinchweld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that can cause glass damage. Clean or repair as necessary.
- Apply Essex U413 Urethane Body Primer, Ford specification WSB-M2G234-C, to minor scratches or any bare metal on the pinchweld caused during removal.
- Do not apply the primer to the existing urethane bed.
- Allow the primer to dry for a minimum of 6-10 minutes before proceeding.
- If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane bead.
- Clean the inside of the new windshield glass with an alcohol-free glass cleaner.
- Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied.
- Making the application approximately 25-mm (1-in) wide, apply two coats of Essex 401 Urethane Glass Prep, Ford specification WSB-M5B280-C2, to the entire inside perimeter of the windshield glass.
- Use a clean shop towel to wipe the glass prep off immediately after each application.
- Using a clean wool applicator, apply Essex 402 Urethane Glass Primer, Ford specification WSB-M2G314-B.
- Cut the applicator tip of Essex 400 HV Urethane High Viscosity Adhesive, Ford specification WSB-M2G316-B, to specification. This will produce a triangular bead during application.
- Apply a uniform 11-mm (0.43-inch) bead of Essex 400 HV Urethane High Viscosity Adhesive, Ford specification WSB-M2G316-B, on top of the existing trimmed urethane bead on the pinchweld.
- Make sure that all gaps in the urethane bead are smoothed into one continuous bead.
- Using the alignment marks made previously, position the windshield glass on the pinchweld.
- Check the glass installation for air or water leaks.
- Install the roof trim panel.
- Install the inside visor. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
- Install the overhead console.
- Install the windshield side garnish moldings.
- Install the interior rear view mirror.
- Install the cowl vent grille. For additional information, refer to FRONT END BODY PANELS .
NOTE:
The urethane must be smooth and free of cuts or contamination. Avoid touching the urethane surface after preparation.
CAUTION:
ALL rust found on the pinchweld must be removed and the pinchweld restored to OEM specifications. If surface rust is found, clean the area down to bare metal. Prime the affected area with OEM recommended curing automotive paint primer and allow to cure. If rust has penetrated the pinchweld metal, use body shop methods to repair the affected area before proceeding.
NOTE:
If reinstalling the removed windshield glass, complete this step and go to step 10. If installing a new windshield glass, skip step 7 and go to step 8.
CAUTION:
Wipe off the urethane glass prep immediately after application before it flash dries.
CAUTION:
Make sure the area of glass prep application aligns with the existing urethane bead on the pinchweld.
CAUTION:
For correct installation, two coats of the glass prep are necessary.
NOTE:
Use a clean wool applicator for each application of the glass prep.
CAUTION:
The urethane glass primer must be thoroughly shaken for proper curing to occur.
CAUTION:
The glass primer must cure for a minimum of five minutes before the windshield glass is installed.
CAUTION:
Do not allow the glass primer to come in contact with the molding. Keep the primer application 2-3 mm (0.07-0.11 in) away from the edge of the molding.
NOTE:
The glass primer application must be over the same area as the glass prep application.
CAUTION:
The urethane bead must have a triangular cross section.
Fig 3: Cutting Applicator Tip Of Essex 400 HV Urethane High Viscosity Adhesive, Ford Specification WSB-M2G316-B, To Specification
CAUTION:
The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
WARNING:
Inadequate or incorrect curing of the urethane adhesive will adversely affect windshield glass retention. After installing urethane bonded glass, the vehicle must not be driven until the urethane has cured. Using Essex 400 HV at 21°C (70°F) and relative humidity above 50%, adequate cure time is typically 24 hours (less at higher temperatures and higher humidity). Follow manufacturer's instructions.
CAUTION:
Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the adhesive bond.
CAUTION:
The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.