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Windshield Glass: Installation

CAUTION: After installing a new urethane-installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time for Essex 400-HV at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperature and humidity vary.) Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive.
CAUTION: Make sure urethanes and primers have not gone beyond the shelf life printed on the containers. Lids should be re-installed after use to maximize actual shelf life, which may be less than what is indicated once lids or seals are removed.
  1. Dry fit the windshield glass. Make alignment marks on glass and sheet metal with tape or non-staining grease pencil.
    2. CAUTION: Avoid scratching the pinch weld area.
    Fig 1: Trimming Remaining Urethane Adhesive On Pinch Weld
    G02238276Courtesy of FORD MOTOR CO.
  2. Trim the remaining urethane adhesive on the pinch weld to within specification.
  3. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld area. Allow 6 to 10 minutes to dry.
  4. If reinstalling the original windshield glass, remove the excess urethane adhesive from the windshield glass.
    5. NOTE: If the molding is already on the windshield glass, proceed to the next step.
  5. Align the "V" notch in the ceramic paint and windshield outside molding at top center. Fully seat the windshield outside molding along the top edge of the windshield glass and along the sides and bottom edges of the windshield glass.
  6. If installing a new windshield glass, clean the windshield glass with an alcohol-free based window cleaner to make sure the ceramic-coated area is clean.
    7. NOTE: Wipe off the glass prep with a clean lint-free cloth immediately after each application because it flash dries.
  7. If installing a new windshield glass, apply urethane glass prep around the surface to be urethaned.
  8. If installing a new windshield glass, apply glass primer to the same area that was in the previous step. Allow five minutes to dry.
  9. Cut the urethane adhesive applicator tip to specification.
    Fig 2: Cutting Urethane Adhesive Applicator Tip
    G02238277Courtesy of FORD MOTOR CO.
    10. CAUTION: If the vehicle is to be driven within 24 hours of urethane application, Urethane Adhesive Essex U-216 must be used due to its one hour cure time.
    Fig 3: Applying Urethane Adhesive To Pinch Weld
    G02238278Courtesy of FORD MOTOR CO.
  10. Apply a bead of urethane adhesive to the pinch weld.
  11. Install the windshield glass aligning it to the marks made previously.
  12. After the glass is set, check for water leaks and add urethane adhesive where needed.
  13. Position the front portion of the headliner.
  14. Install the front door weatherstrips.
  15. Install the sun visors and sun visor clips.
  16. Install the windshield side garnish moldings.
    Fig 4: Installing Windshield Side Garnish Moldings
    G02238279Courtesy of FORD MOTOR CO.
  17. Install the instrument panel defroster opening grille
    1. Position the instrument panel defroster opening grille.
    2. Connect the electrical connectors.
    3. Install the instrument panel defroster opening grille
    Fig 5: Installing Instrument Panel Defroster Opening Grille
    G02238280Courtesy of FORD MOTOR CO.
  18. Install the interior rear view mirror. For additional information, see INTERIOR REAR VIEW MIRROR .
  19. Install the cowl grille.
  20. Install and adjust the wiper blade and mounting arms. For additional information, see WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT .
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