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Windshield Reseal

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATIONS

Item Specification
Dow Urethane Adhesive Betaseal® Express -
Sika Urethane Adhesive Sika Tack ASAP -
Ultra-Clear Spray Glass Cleaner ZC-23 ESR-M14P5-A
  1. Remove the cowl panel grille. For additional information, refer to REMOVAL AND INSTALLATION .
  2. Position the LH and RH weatherstrips aside.
    Fig 1: Locating Weatherstrip
    G03989074Courtesy of FORD MOTOR CO.
  3. Remove the LH and RH A-pillar trim panels.
    Fig 2: Locating LH & RH A-Pillar Trim Panels
    G04658891Courtesy of FORD MOTOR CO.
  4. Remove the LH and RH sun visors.
    1. Remove the 4 screws.
    2. Disconnect the electrical connectors.
    3. Remove the visors and the clips.
    Fig 3: Locating LH & RH Sun Visors
    G04658892Courtesy of FORD MOTOR CO.
  5. If equipped, remove the overhead console.
  6. Open the assist handle screw covers.
    Fig 4: Identifying Assist Handle Screw Covers
    G03989077Courtesy of FORD MOTOR CO.
  7. Remove the 2 assist handle screws and the assist handle.
  8. Lower the front portion of the headliner and block with a suitable material.
  9. Clean the interior and exterior of the windshield glass surface with glass cleaner.
  10. Cut the urethane adhesive applicator tip to 6 mm (0.23 in).
    Fig 5: Identifying Urethane Adhesive Applicator Tip
    G04658894Courtesy of FORD MOTOR CO.
    11. NOTE:
    1. Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.
    2. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
  11. Apply urethane adhesive over top of the existing urethane adhesive.
    • Apply the urethane to the top and sides of the windshield from the interior of the vehicle.
    • Apply the urethane to the bottom of the windshield from the exterior of the vehicle.
    12. CAUTION: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
  12. After the urethane has cured, check the windshield seal for air or water leaks through the urethane bead and add urethane adhesive as necessary.
  13. Position the front portion of the headliner.
  14. Position the LH and RH assist handles and install the 2 screws.
    Fig 6: Locating LH And RH Assist Handles And Screws
    G04658895Courtesy of FORD MOTOR CO.
  15. Close the assist handle screw covers.
    Fig 7: Identifying Assist Handle Screw Covers
    G03989077Courtesy of FORD MOTOR CO.
  16. If equipped, install the overhead console.
  17. Install the LH and RH sun visors.
    1. Install the clips.
    2. Connect the electrical connectors and install the visors.
    3. Install the 4 screws.
    Fig 8: Identifying LH & RH Sun Visors
    G04658897Courtesy of FORD MOTOR CO.
  18. Install the LH and RH A-pillar trim panels.
    Fig 9: Locating LH & RH A-Pillar Trim Panels
    G04658898Courtesy of FORD MOTOR CO.
  19. Install the LH and RH weatherstrips.
    Fig 10: Locating Weatherstrip
    G03989074Courtesy of FORD MOTOR CO.
  20. Install the cowl panel grille. For additional information, refer to REMOVAL AND INSTALLATION .
  21. Clean the interior and exterior windshield glass with glass cleaner.
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