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Windshield Glass: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that could cause glass damage.
  2. Apply Urethane Body Primer WSB-M2G234-C (black) to any exposed metal on the pinch weld.
    • Do not apply the primer to the existing urethane bead.
    • Let the primer dry for a minimum of 6-10 minutes before proceeding.
  3. If re-installing the same windshield glass, remove all remaining traces of urethane sealant.
  4. Install the windshield header seal on the windshield
  5. Properly align the windshield glass to the body, mark the windshield glass, and remove the windshield glass from the vehicle.
    1. Place the windshield glass in the opening, and center it from top to bottom and side to side with about equal clearance on all sides.
    2. Make alignment marks on each of the four sides of the windshield glass.
    3. Remove the windshield glass from the vehicle, and place it inside up.
  6. Clean the inside of the windshield glass with an alcohol-free cleaner.
    7. NOTE: Apply with deliberate strokes, making sure not to overlap the applied area
  7. Apply Urethane Glass Primer Wipe WSB-M5B280-C2 (red) to the entire inside perimeter of the windshield glass. Wipe off immediately after each application.
  8. Apply Urethane Glass Primer WSB-M2G314-B (black) to the entire inside perimeter of the windshield glass. Allow a minimum of 5 minutes drying time.
    9. NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane sealant
    Fig 1: Applying Wide Bead Of Urethane High Viscosity Adhesive To Entire Primed Area Of Windshield Glass
    G01441222Courtesy of FORD MOTOR CO.
  9. Apply an 11-mm (0.43-inch) wide bead of Urethane High Viscosity Adhesive WSB-M2G316-B to the entire primed area of the windshield glass.
    10. CAUTION: After replacing the urethane-installed glass, the vehicle must not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane can adversely effect the strength of the urethane sealant bond
    NOTE: Before installing the windshield glass, open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed
    Fig 2: Positioning Windshield Glass On Vehicle Pinch Weld
    G01441223Courtesy of FORD MOTOR CO.
  10. Position the windshield glass on the vehicle pinch weld, aligning it with the marks.
  11. Position the windshield glass stops on the vehicle. Make sure the windshield glass is aligned and rivet the stops in position, using a 385974-S rivet.
    Fig 3: Positioning Windshield Glass Stops On Vehicle
    G01441224Courtesy of FORD MOTOR CO.
  12. Wipe off any excess urethane sealant and apply a 6-mm (0.23-inch) bead of Pumpable Foam Dam ESB-M4G309-A between the windshield header seal and the urethane sealant.
  13. Fill the cavities between both the LH and RH sides of the windshield header seal and the sheet metal, using RTV Sealer ESB-M4G92-A for a total length of 50 mm (2 inches) from the base of the A-pillars.
  14. Install the inside rear view mirror; for additional information, refer to REAR VIEW MIRRORS .
  15. Install the roof trim panel; for additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  16. Install (push on) the LH and RH A-pillar mouldings.
  17. Instal the cowl top vent panel; for additional information, refer to FRONT END BODY PANELS .
  18. Install the windshield wiper pivot arms; for additional information, refer to WIPERS AND WASHERS .
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