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Windshield Glass: Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not drive vehicle until the urethane seal has cured. Follow urethane manufacturer's curing directions. Inadequate or incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if the doors are closed.
  1. Dry fit the windshield glass, making alignment marks with tape or a non-staining grease pencil.
    2. 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: Do not scratch the pinch weld area. For minor scratches or exposed metal on the pinch weld, see manufacturer's recommendations.
  2. Trim the remaining urethane adhesive on the pinch weld to within the specification.
    • The existing urethane adhesive surface should be smooth and free of cuts and contamination.
    3. Fig 1: Trimming Pinch Weld Urethane Adhesive With Specification
    G03880554Courtesy of FORD MOTOR CO.
  3. If reinstalling the original windshield glass, remove the excess urethane adhesive and the windshield molding.
  4. Clean the inside of the windshield glass surface with glass cleaner making sure the ceramic-coated area is clean.
    5. NOTE: Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure.
    NOTE: Sika uses the same black primer for the glass and pinch weld area.
  5. If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
  6. Cut the urethane adhesive applicator tip to specification.
    7. Fig 2: Cutting Urethane Applicator Tip With Specification
    GF0001997Courtesy of FORD MOTOR CO.
    NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.
  7. Apply 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.
  8. Install the windshield glass, aligning it to the marks previously made.
    9. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air and water leaks.
  9. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed.
  10. If necessary, remove excess urethane adhesive from the exterior surface of the windshield glass.
  11. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS article.
  12. Reposition the front portion of the headliner.
  13. Install the LH and RH sun visors and visor clips.
    • If equipped, connect the electrical connectors.
  14. Install the interior rear view mirror. For additional information, refer to REAR VIEW MIRRORS article.
  15. Position the overhead console and install the 2 overhead console screws.
    • If equipped, connect the electrical connector.
  16. Install the 2 windshield side garnish moldings.
  17. Install the LH and RH A-pillar trim panels. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
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