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Windshield Glass: Removal

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the cowl vent grille. For additional information, refer to FRONT END BODY PANELS .
  2. Remove the interior rear view mirror.
  3. Remove the windshield side garnish mouldings. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  4. Remove the overhead console.
  5. Remove the inside visor. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  6. Lower the front portion of the headliner.
  7. Cover the seats, instrument panel and hood to prevent possible damage.
  8. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinchweld area.
    • Use a clean rag or oil-free compressed air.
    9. NOTE: Refer to manufacturer's instructions before using the tool.
  9. Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive.
    10. WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle.
    CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinchweld during glass removal.
    NOTE: Insert the blade into the Cut-Out Knife so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the replacement windshield glass.
    NOTE: Support the windshield glass to prevent the glass from dropping while cutting the urethane adhesive.
    Fig 1: Identifying Special Tool
    G04646268
  10. Insert the Interior Auto Glass Cut-Out Knife at the upper center of the windshield glass and work toward the bottom corners.
  11. Using the special tool, distance the windshield from the body.
    Fig 2: Identifying Distance Windshield From Body
    G04646269
  12. Insert the Interior Auto Glass Cut-Out Knife into the bottom of the urethane adhesive and cut from corner to corner.
    13. WARNING: Removing the windshield glass requires more than one technician.
    NOTE: If reinstalling the windshield glass, tape the windshield at the windshield stops to aid in alignment of the glass during installation.
  13. Carefully remove the windshield glass from the vehicle and place on a stable work surface.
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