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Rear Window Glass: Installation

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: When installing urethane installed glass parts, the vehicle must not be driven until the urethane has cured. At temperatures above 21°C (70°F) and relative humidity above 50%, adequate cure time is typically 24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate or incorrect curing can adversely affect the retention of the back window glass.
NOTE: On Taurus vehicles only, allow for a 5mm gap between roof, body sides and the back window glass.
  1. Dry fit the back window glass to the existing urethane adhesive on the body pinch weld. Align the glass in the opening for a uniform fit.
  2. Use a non-permanent pencil to make alignment marks to aid in the installation alignment of the back window glass.
  3. Remove the back window glass.
    4. NOTE: Avoid scratching the pinch weld area. A portion of the pinch weld will be visible once the rear window glass is installed.
    Fig 1: Removing Urethane Adhesive
    G01596208Courtesy of FORD MOTOR CO.
  4. Trim the urethane adhesive on the pinch weld.

    The urethane adhesive must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane adhesive surface after preparation.

  5. Apply urethane metal primer to any exposed or damaged metal on the pinch weld.
  6. If installing the original back window glass, remove the excess urethane adhesive.
  7. Clean the back window glass with a non-alcohol based window cleaner.
    8. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries.
  8. If installing a new back window glass, apply urethane glass prep twice to the area to be urethan
  9. If installing a new back window glass, apply urethane glass primer to the same area that was in the previous step. Allow five minutes to dry.
  10. Cut the urethane adhesive applicator tip to specification.
    Fig 2: Cutting Urethane Adhesive Applicator Tip
    G01596209Courtesy of FORD MOTOR CO.
    11. CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, urethane adhesive Essex U-216 must be used due to its one-hour cure time.
    Fig 3: Applying Urethane Adhesive
    G01596210Courtesy of FORD MOTOR CO.
  11. Apply urethane adhesive on top of the existing urethane adhesive bead on the pinch weld

    Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.

    12. NOTE: On sable vehicles only, adjust the back window glass on the setting blocks.
    Fig 4: Installing Back Window Glass On Pinch Weld
    G01596211Courtesy of FORD MOTOR CO.
  12. Install the back window glass on the pinch weld. Align the back window glass to the body using the alignment marks.
  13. Inspect the back window glass for air or water leaks through the urethane adhesive seal.
  14. Install the headliner.
  15. Connect the LH and RH rear window defroster connectors.
    Fig 5: Connecting Rear Window Defroster Connectors
    G01596212Courtesy of FORD MOTOR CO.
  16. Install the high mount stop lamp. For additional information, refer to EXTERIOR LIGHTING .
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