Windshield Glass: Removal

WARNING: This page is about a different car, the 2009 Mercury Milan, 2009 Lincoln MKZ, and 2009 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If the windshield glass is being removed to repair a dust/water leak, remove and reinstall the existing windshield glass.

Remove the A-pillar trim panels. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
Remove the sun visors.
Remove the interior mirror. For additional information, refer to REAR VIEW MIRRORS article.
Partially lower the front portion of the headliner near the windshield header and block with suitable material. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
Remove the cowl panel grille. For additional information, refer to FRONT END BODY PANELS article.
Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinchweld area.
- Use a clean shop towel or oil-free, compressed air.

NOTE: Refer to manufacturer's instructions before using the Interior Auto Glass Cut-Out Knife Kit (Electric).

Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit (Electric) when cutting.

WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.

WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.

CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinchweld during glass removal.

NOTE: Insert the blade into the Interior Auto Glass Cut-Out Knife Kit (Electric) so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the replacement windshield glass.

NOTE: Support the windshield glass to prevent the glass from dropping while cutting the urethane adhesive.

Insert the Interior Auto Glass Cut-Out Knife Kit (Electric) at the upper center of the windshield glass and work toward the bottom corners.

Fig 1: Cutting Urethane Adhesive From Glass

Courtesy of FORD MOTOR CO.

Using The Pumper, distance the windshield glass from the body.

Fig 2: Distancing Windshield Glass From The Body

Courtesy of FORD MOTOR CO.

Insert the Interior Auto Glass Cut-Out Knife Kit (Electric) into the bottom of the urethane adhesive and cut from corner to corner.
Carefully remove the windshield glass from the vehicle and place on a stable work surface.