Windshield Glass: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the cowl vent grille. Refer to FRONT END BODY PANELS .
Remove the interior rear view mirror.
Remove the windshield side garnish mouldings. Refer to INTERIOR TRIM AND ORNAMENTATION .
Remove the overhead console.
Remove the inside visor. Refer to INTERIOR TRIM AND ORNAMENTATION .
Lower the front portion of the roof trim panel.
Cover the seats, instrument panel and hood to prevent possible damage.
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.

NOTE: Refer to manufacturer's instructions before using the tool.

Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive.

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 (03100).

NOTE: Support the windshield glass to prevent the glass from dropping while cutting the urethane adhesive.

Fig 1: Inserting The Interior Auto Glass

Courtesy of FORD MOTOR CO.

Insert the Interior Auto Glass Cut-Out Knife at the upper center of the windshield glass and work toward the bottom corners.
To aid the in cutting the urethane adhesive along the cowl, insert the Pumper tool at the top center of the windshield and inflate.

Fig 2: Inserting The Pumper Tool At The Top Center Of The Windshield
Courtesy of FORD MOTOR CO.
Insert the Interior Auto Glass Cut-Out Knife into the bottom of the urethane adhesive and cut from corner to corner.

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 installation.

Carefully remove the windshield glass from the vehicle and place on a stable work surface.