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Windshield Reseal: Procedure

  1. Remove the windshield side garnish mouldings.
    Fig 1: Removing Windshield Side Garnish Mouldings
    G03916842Courtesy of FORD MOTOR CO.
  2. Remove the interior rear view mirror.
  3. Remove the overhead console.
  4. If equipped, remove the roof opening panel trim.
  5. Remove the sun visors.
    1. Remove the sun visor screws.
    2. Remove the sun visors.
      • If equipped, disconnect the electrical connector.
        Fig 2: Removing Sun Visor Screws
        G03916843Courtesy of FORD MOTOR CO.
  6. Remove the sun visor clips.
    1. Remove the sun visor clip screws.
    2. Remove the sun visor clips.
      Fig 3: Removing Sun Visor Clip Screws
      G03916844Courtesy of FORD MOTOR CO.
  7. Partially lower the front portion of the headliner near the windshield upper opening and block with a suitable material.
  8. Remove the cowl grille. For additional information, refer to FRONT END BODY PANELS .
  9. Clean the edge formed by the existing urethane and the glass on the inside at the top and sides, and outside on the bottom of the windshield with an alcohol free cleaner.
  10. Cut the urethane applicator tip to specification.
    Fig 4: Cutting Urethane Adhesive Applicator Tip To Specification
    G03890979Courtesy of FORD MOTOR CO.
    11. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.
  11. Apply a bead of urethane adhesive essex 400-HV to the cleaned area.
    12. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
  12. Backfill the urethane application and clean the excess.
    13. CAUTION: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
  13. After the urethane has cured, check the windshield seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
  14. Install the cowl grille. For additional information, refer to FRONT END BODY PANELS .
  15. Install the front portion of the headliner.
  16. Install the sun visor clips.
    1. Position the sun visor clips.
    2. Install the screws.
      Fig 5: Installing Sun Visor Clips
      G03916846Courtesy of FORD MOTOR CO.
  17. Install the sun visors.
    1. Position the sun visors.
      • If equipped, connect the electrical connector.
    2. Install the screws.
      Fig 6: Installing Screws
      G03916847Courtesy of FORD MOTOR CO.
  18. If equipped, install the roof opening panel trim.
  19. Install the overhead console.
  20. Install the interior rear view mirror. Make sure the interior rear view mirror is securely seated on the mounting tab.
  21. Install the windshield side garnish.
    Fig 7: Installing Windshield Side Garnish
    G03916842Courtesy of FORD MOTOR CO.
  22. Clean the interior and exterior of the windshield glass with an alcohol free cleaner.
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