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Windshield Reseal

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
MATERIALS

Item Specification
Urethane Adhesive Essex 400-HV WSB-M2G316-B
  1. Remove the windshield wiper pivot arms (17526). For additional information, refer to WIPERS AND WASHERS .
  2. Remove the cowl top vent panel (022A68).
  3. Remove the A-pillar trim panels. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  4. If equipped, remove the overhead console.
    • Remove the screw.
    • Remove the overhead console.
    • Disconnect the electrical connectors.
    Fig 1: Removing Overhead Console
    G02767257Courtesy of FORD MOTOR CO.
  5. If equipped, remove the dome lamp assembly.
    1. Pry the dome lamp from the headliner.
    2. Disconnect the dome lamp electrical connector.
    Fig 2: Removing Dome Lamp Assembly
    G02767258Courtesy of FORD MOTOR CO.
  6. Remove the sun visors. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  7. Remove the interior rear view mirror. For additional information, refer to REAR VIEW MIRRORS .
  8. Clean the edge formed by the existing urethane and the glass on the inside at the top and sides, and outside on the bottom of the windshield with an alcohol free cleaner.
  9. Cut the urethane applicator tip to specification.
    Fig 3: Cutting The Urethane Applicator Tip
    G02767259Courtesy of FORD MOTOR CO.
    10. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.
  10. Apply a bead of Urethane Adhesive Essex 400-HV to the cleaned area.
    11. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
  11. Backfill the urethane application and clean the excess.
    12. CAUTION: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
  12. After the urethane has cured, check the windshield seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
  13. Install the interior rear view mirror. For additional information, refer to REAR VIEW MIRRORS .
  14. Install the sun visors. For additional information, refer to REAR VIEW MIRRORS .
  15. If equipped, install the dome lamp assembly.
  16. If equipped, install the overhead console.
  17. Install the A-pillar trim panels. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  18. Install the cowl top vent panel.
  19. Install the windshield wiper pivot arms. For additional information, refer to WIPERS AND WASHERS .
  20. Clean the exterior and interior of the windshield glass with an alcohol free cleaner.
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