Section 01-11: Glass, Frames and Mechanisms
1996 F-150, F-250, F-350, F-Super Duty and Bronco Workshop Manual
REMOVAL AND INSTALLATION

Windshield Glass

Removal

  1. Remove the windshield wiper mounting arm and pivot shafts (17566) as outlined in Section 01-16.

  1. Remove all mouldings, glass stops and retainers.



    Windshield Exterior Moulding F-Series





    ItemPart NumberDescription
    103045Windshield Header Seal
    (RH Upper)
    203137Windshield Outside Side Moulding (LH Upper)
    303137Windshield Outside Side Moulding (LH)
    403148Windshield Outside Moulding (Lower)
    503136Windshield Outside Side Moulding (RH)
    642413Clip, Reveal Moulding
    703100Windshield Glass
    829100Clip, Reveal Moulding
  1. Remove inside rear view mirror (17700). Refer to Section 01-09.

  1. Spray Equalizer Cutting Lubricant ECL-784 around windshield urethane cutting area.

  1. NOTE: On bonded, encapsulated parts, turn blade of cutting knife over so flat side is against pinch-weld. If blade is not turned over, it may cut or damage plastic encapsulation.

    Cut urethane around windshield with utility knife.

  1. Insert Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent into urethane at lower center of windshield and cut through the urethane sealant around the entire windshield glass (03100).





  1. Remove the windshield glass with aid of an assistant.

  1. NOTE: If the urethane has cured all the way through, it will be necessary to remove enough urethane to leave only a 1.5mm (1/16 inch) thick layer on the sheet metal.

    Remove any excess urethane, using care not to smear the urethane on component parts.

  1. Check flange sealing area for damaged sheet metal or foreign objects which may cause glass breakage. Repair sheet metal if necessary.

 

Installation

 CAUTION: Use only urethane for service of air and water leaks in urethane seal.

 CAUTION: When replacing urethane installed glass parts, the vehicle should not be driven until the urethane has cured. This will prevent the windshield from being jarred out of position.

 CAUTION: Leave door windows down slightly and do not slam doors closed until urethane has cured.

NOTE: Installation of glass with urethane-type seal is performed using Urethane Kit E0AZ-19562-A. The kit contains tools and materials required for glass installation. Materials listed in this procedure are part of this kit.

NOTE: Repair any damage to sheet metal flange.

NOTE: If existing (fully cured) urethane remains on the windshield opening flange, the new urethane should be applied on top of the existing urethane. However, at no point should the existing urethane material exceed 2.54mm (0.10 inch) above the sheet metal flange. If necessary, reduce the height of the existing urethane using a razor blade or utility knife.

  1. Using applicator supplied with kit, apply Urethane Metal Primer WSB-M2G234-C to windshield opening flange, where bare or painted sheet metal is exposed. Allow a minimum of ten minutes for urethane metal primer surface to dry.





  1. Install Polyvinyl Chloride (Foam Dam) Tape with self-adhesive back around window opening at end of metal flange, and at uppermost side of seal plane along cowl top outer panel (02012).





  1. Place the windshield glass on a low, stable work surface, inside up.

  1. Clean the windshield glass and install the inside rear view mirror bracket (17698) with Rearview Mirror Adhesive D9AZ-19554-CA or equivalent meeting Ford specification ESB-M2G176-A as described in Section 01-09.

  1. NOTE: Wipe off urethane glass cleaner immediately after application because cleaner flash-dries.

    Using applicator supplied with kit, wipe the outer 13mm (1/2 inch) of the inside windshield glass periphery with Urethane Glass Wipe WSB-M5B280-S2. Immediately following application, before evaporation occurs, wipe off with a lint free cloth. Repeat application.





  1. Use glass spacers to properly align windshield glass to body. Windshield glass must be centered so that the difference between the side margins is no more than 3.0mm (0.11 inch) along the entire "A" pillar. Mark alignment points with masking tape or crayon on four sides of both glass and opening.





  1. Remove windshield glass from vehicle and place on work table with the inside facing up.

  1. Thoroughly shake and stir Urethane Glass Primer WSB-M2G314-B to make sure pigment mixes uniformly.

  1. Using a kit applicator, apply primer to the outer 13mm (1/2 inch) of the inside of the windshield glass. Allow at least five minutes drying time.





  1. Apply an even bead of Urethane Adhesive WSB-M2G316-B around entire windshield glass edge using an air pressure cartridge gun. Air line pressure should be approximately 276 kPa (40 psi). The bead should be triangular in shape, 14mm (0.55 inch) high, and 8.0mm (0.33 inch) at base.





  1. Install the windshield glass onto the vehicle, taking care to align the marks on the windshield glass and the body. This must be done before adhesive skins over. Apply enough pressure to seat the windshield glass with the adhesive into the opening.





  1. Install the retainers, glass stops and mouldings.






    ItemPart NumberDescription
    103045Windshield Header Seal
    (RH Upper)
    203137Windshield Outside Side Moulding (LH Upper)
    303137Windshield Outside Side Moulding (LH)
    403148Windshield Outside Moulding (Lower)
    503136Windshield Outside Side Moulding (RH)
  1. Install windshield wiper mounting arm and pivot shaft, and inside rear view mirror.