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Home >> Ford >> 2002 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2994 (Windows & Glass - Glass, Frames And Mechanisms -- F250-F550 Super Duty) >> Removal And Installation >> Windshield Glass >> Installation

Windshield Glass: Installation

WARNING: This page is about a different car, the 2011 Ford Pickup, 2011 Ford F550 Super Duty, 2011 Ford F450 Super Duty, and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Dry-fit the new windshield glass on the existing urethane adhesive bead on the pinch weld.
    • Position the windshield glass on the pinch weld.
    • Center the windshield glass in the opening.
    • Adjust the windshield glass stop blocks 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 and moulding assembly from the windshield opening and place on a stable work surface with the interior side of the glass facing up.
  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 the manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.

    Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinch weld.

    Fig 1: Trimming Urethane Adhesive Using Appropriate Tool
    G07486029Courtesy of FORD MOTOR CO.
  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 windshield 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 new windshield glass with glass cleaner.
    • Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied.
  7. If installing a new windshield glass, apply glass primer according to the manufacturer's instructions. Allow at least 6 minutes to dry.
    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.
  8. Cut the urethane adhesive applicator tip to specification.
    Fig 2: Identifying Urethane Adhesive Applicator Tip Cutting Dimension
    G07486030Courtesy of FORD MOTOR CO.
  9. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield near the center, making sure there are no gaps in the bead.
    NOTE: Use either the Air Caulking Gun or a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and a continuous bead.
    NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
  10. Using the alignment marks made previously, position the windshield glass on the pinch weld.
    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.
  11. Check the glass installation for air or water leaks.
    NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
  12. Install the sun visors.
  13. Install the overhead console. For additional information, refer to INSTRUMENT PANEL AND CONSOLE .
  14. Install the A-pillar trim panels. For additional information, refer to INTERIOR TRIM & ORNAMENTATION .
  15. Install the interior rear view mirror. For additional information, refer to REAR VIEW MIRROR .
  16. Install the cowl panel grille. For additional information, refer to BODY PANEL SYSTEM - FRONT END BODY PANELS .
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