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Windshield Glass: Installation

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Dry-fit the windshield glass on the existing urethane adhesive bead on the pinch weld.
    • Position the windshield glass on the pinch weld.
    • Center the glass in the opening.
    • Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
    • Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass stop blocks) on the windshield glass and the body.
  2. After the dry-fit alignment, remove the glass from the body opening and place on a stable work surface with the interior side of the glass facing upward.
    3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
    NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.
    Fig 1: Trimming Urethane With Appropriate Tool With Specifications
    G07789163Courtesy of FORD MOTOR CO.
  3. Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane adhesive on the pinchweld.
  4. Using a clean shop towel, brush or oil-free, compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during glass removal.
  5. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive bead.
  6. Clean the inside of the windshield glass surface with glass cleaner.
    • Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied.
    7. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the MATERIAL CHART  in this procedure.
  7. If installing a new windshield glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
  8. Cut the urethane adhesive applicator tip to specification.
    Fig 2: Identifying Urethane Adhesive Applicator Tip Cutting Dimension With Specifications
    G07789164Courtesy of FORD MOTOR CO.
    9. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and continuous bead.
    NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
    Fig 3: Identifying Urethane Adhesive Bead Applying Dimension With Specifications
    G07789165Courtesy of FORD MOTOR CO.
  9. Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield glass near the center, making sure there are no gaps in the bead.
    10. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
    NOTE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.
  10. Using the alignment marks made previously, position the windshield glass on the pinch weld.
    11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
  11. After the urethane adhesive has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
  12. Install the cowl panel grille. For additional information, Refer to FRONT END BODY PANELS -- FUSION, MILAN & MKZ article.
  13. Install the headliner. For additional information, Refer to INTERIOR TRIM & ORNAMENTATION -- FUSION, MILAN & MKZ article.
  14. If equipped, install the rain sensor. For additional information, Refer to WIPER SYSTEM & WASHER SYSTEM -- FUSION, MILAN & MKZ article.
  15. Install the interior mirror. For additional information, Refer to REAR VIEW MIRRORS -- FUSION, MILAN & MKZ article.
  16. Install the sun visors.
  17. Install the A-pillar trim panels. For additional information, Refer to INTERIOR TRIM & ORNAMENTATION -- FUSION, MILAN & MKZ article.
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