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Windshield Glass: Installation

WARNING: This page is about a different car, the 2002 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: After installing the new urethane-installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13° C (55° F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond.
  1. Dry fit the replacement windshield glass to the existing urethane bed on the body pinch weld. Align the windshield in the opening for uniform fit and adjust setting blocks as needed for best fit.
  2. Use tape or non-permanent marking pencil to make alignment marks on the windshield (preferably at the setting blocks), and the body to aid in the installation alignment of the replacement windshield.
  3. After alignment, remove the windshield glass and molding assemblies from the vehicle and place on a stable work surface.
    4. CAUTION: Care must be taken to avoid scratching the pinch weld.
    Fig 1: Trimming Remaining Urethane Adhesive
    G02165198Courtesy of FORD MOTOR CO.
  4. Trim the remaining urethane adhesive on the pinch weld. The urethane must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.
    5. CAUTION: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM recommended curing automotive paint primer and allow to cure properly. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding.
  5. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair surface as necessary.
  6. Use the wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to ten minutes to dry.
  7. If re-installing the same windshield glass that was removed, trim the remaining urethane adhesive from the windshield surface, leaving a thin layer for adhering to the new urethane bead.
  8. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
    9. NOTE: If the molding is already on the windshield glass, proceed to the next step.
  9. Align the "V" notch in the ceramic paint and windshield outside molding at top center. Fully seat the windshield outside molding along the top edge of the windshield glass and along the sides and bottom edges of the windshield glass.
  10. Remove the dual lock windshield glass stop adhesive backing.
    11. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area.
  11. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be prepped.
  12. If installing a new windshield glass, apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the previous step. Allow five minutes to dry.
  13. Cut the urethane adhesive applicator tip to specification.
    Fig 2: Cutting Urethane Adhesive Applicator Tip
    G02165199Courtesy of FORD MOTOR CO.
    14. CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, Urethane Adhesive Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one-hour cure time.
    Fig 3: Applying Urethane Adhesive
    G02165200Courtesy of FORD MOTOR CO.
  14. Apply a bead of Urethane Adhesive Essex 400-HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld just outside the foam dam.
    15. CAUTION: Before installing the windshield glass, open the windows slightly to prevent the windshield from being pushed out by air pressure as the door is closed.
    NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
  15. Install the windshield glass on the vehicle, aligning it with marks made previously.
  16. Check the windshield installation for air or water leaks through the urethane bead and add urethane adhesive where needed.
  17. Place two strips of duct tape onto the windshield glass and secure it to the roof panel. This will help avoid misalignment while the urethane cures.
  18. Install the windshield drip moldings.
    • Install the eight screws.
  19. Install the instrument panel defrost opening grille assembly.
    • Connect the electrical connector.
    Fig 4: Installing Instrument Panel Defrost Opening Grille Assembly
    G02165201Courtesy of FORD MOTOR CO.
  20. Connect the two heated wiper park grid electrical connectors.
  21. Position the headliner.
  22. Install the weatherstrips.
  23. Install the LH and RH windshield side garnish moldings. For additional information, see TRIM PANEL - WINDSHIELD SIDE GARNISH MOLDING .
  24. Install the sun visor clips and screws.
    Fig 5: Installing Sun Visor Clips
    G02165202Courtesy of FORD MOTOR CO.
  25. Install the sun visors and screws.
    • Connect the electrical connectors.
    Fig 6: Installing Sun Visors
    G02165203Courtesy of FORD MOTOR CO.
  26. Install the rain sensor module. For additional information, see MODULE - RAIN SENSOR .
  27. Install the rear view mirror. For additional information, see MIRROR - INTERIOR REAR VIEW .
  28. Install the cowl vent screen.
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