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Windshield Glass: Installation

CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the urethane has cured. Adequate cure time is specified on the drive away chart for each urethane product as the temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield.
NOTE: For additional material guidelines, refer to the manufacturer's installation information.
  1. Dry fit the windshield glass to the existing urethane adhesive bead on the body pinch weld. Align the windshield glass in the opening for a uniform fit.
  2. Use a non-permanent pencil to make alignment marks on the windshield glass at the setting blocks and the body to aid in the installation alignment of the windshield glass.
  3. Remove the windshield glass.
    4. NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see manufacturer's recommendations.
  4. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm base of original equipment urethane on the pinchweld.
    5. Fig 1: Measuring Urethane With Appropriate Tool
    G03987089Courtesy of FORD MOTOR CO.
  5. If installing the original windshield glass, remove the excess urethane adhesive.
  6. Clean the inside of the windshield glass surface with a non-alcohol based glass cleaner.
    7. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure.
    NOTE: Sika uses the same black primer for the glass and pinch weld area.
  7. If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
  8. Cut the urethane adhesive applicator tip to specification.
    9. Fig 2: Cutting Urethane Adhesive Applicator Tip To Specification
    G03989130Courtesy of FORD MOTOR CO.
    NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and continuous bead.
  9. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the windshield near the center.
    10. Fig 3: Applying Urethane Adhesive (With Specifications)
    G03989131Courtesy of FORD MOTOR CO.
  10. Install the windshield glass on the vehicle aligning it with the markings made previously.
    11. CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the urethane has cured. Adequate cure time is specified on the drive away chart for each urethane product as the temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield.
  11. After the urethane has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
  12. Position the headliner back.
  13. If equipped, install the dome lamp assembly. For additional information, refer to INTERIOR LIGHTING article.
  14. Install the 2 sun visor clips, the LH and RH sun visors, and the 8 screws.
    15. NOTE: When installing the windshield side garnish moldings, be sure the alignment tabs are positioned correctly.
  15. Install the RH and LH windshield side garnish moldings.
  16. Install the LH and RH front door weatherstrips.
  17. Install the interior rear view mirror. For additional information, refer to REAR VIEW MIRRORS article.
  18. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS article.
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