Windshield Glass: Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. 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. Adequate cure time is specified on the drive away chart for each urethane product as the temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield.

NOTE: For additional material guidelines, refer to the manufacturer's installation information.

Dry-fit the windshield glass by centering it side-to-side and by adjusting the blocks (if equipped) to get the correct position of the part top-to-bottom. Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body.

NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see the manufacturer's recommendations.

Fig 1: Trimming Urethane With Appropriate Tool

Courtesy of FORD MOTOR CO.

Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane on the pinch weld.
If reinstalling the original windshield glass, remove any excess urethane adhesive from the glass.
If installing a new windshield glass, clean the inside of the glass surface with glass cleaner to make sure the ceramic-coated area is clean.

CAUTION: Be sure to use the same brand of cure-rate products for the adhesive primer. Do not mix different brands of urethane and primer. Refer to the MATERIAL SPECIFICATION in the procedure.

NOTE: Sika uses the same black primer for the glass and pinch weld area.

If installing a new windshield glass, apply urethane glass primer according to the manufacturer's instructions. Allow at least 6 minutes to dry.
Cut the applicator tip to specification.

Fig 2: Cutting Urethane Adhesive Applicator Tip
Courtesy of FORD MOTOR CO.

NOTE: Use either a high-ratio, electric or battery-operated caulk gun that applies the urethane with less effort and a continuous bead.

Fig 3: Applying Urethane Adhesive On Top Of Existing Trimmed Urethane Adhesive Bead On Pinch Weld

Courtesy of FORD MOTOR CO.

Apply a bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the windshield near the center.

CAUTION: Open a window to prevent the windshield glass from being pushed out by air pressure when a door is closed.

Using the alignment marks install the windshield glass.

NOTE: The urethane adhesive must cure for a minimum of 1 hour before testing for air or water leaks.

After the urethane cures, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
Install the front portion of the headliner.
Install the interior rear view mirror. For additional information, refer to REAR VIEW MIRRORS .
If equipped, install the overhead console. For additional information, refer to INSTRUMENT PANEL AND CONSOLE .
Remove the tape from the defroster housing.
Install the instrument panel defroster opening grille assembly.
- If equipped, connect the electrical connectors.
  
  Fig 4: Installing Instrument Panel Defroster Opening Grille Assembly
  Courtesy of FORD MOTOR CO.
Install the RH and LH A-pillar trim panels.
Install the sun visors and clips.
Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .