General Procedures - Fixed Glass

Special Service Tools / General Equipment

Materials

Repair

All vehicles

1. 1
   • The fixed glass is a windshield and is equipped with a camera bracket.
   • The fixed glass is a windshield and is equipped with bonded moldings.
   • The fixed glass is encapsulated with RIM.

   Select the best repair method for the type of glass being replaced.
   

   1. Cold Knife Method – A cold knife is used to cut the urethane from the outside of the vehicle, provided the blade can reach the bead.
      Use general equipment: Cold Knife.

   2. Power Tool Method – Various power tools are used to cut the urethane from inside the vehicle using a cutting or oscillating blade.
      Use special service tool: Power Fixed Glass Removal Tool.

   3. Piano Wire Method – Piano wire is used to cut the urethane from inside and outside the vehicle with the assistance of a helper.
2. 2
   When using the cold knife method, apply tape to protect the perimeter of the window opening from paint damage. Multiple layers of tape may be required.
3. 3
   
   
   

   NOTICE: The new or used fixed glass must be installed within 2 hours after the urethane adhesive is cut. The exposed cut surfaces of the urethane oxidize and become inactive within 2 hours, reducing the effectiveness of the repair bond.

   NOTICE: To prevent rust formation, use extreme care not to scratch the paint or primer or damage the pinch weld flange during glass removal.

   NOTICE: Take precautions to avoid damaging other components when cutting the urethane.

   • The fixed glass is a windshield and is equipped with a camera bracket.
   • The fixed glass is a windshield and is equipped with bonded moldings.
   • The fixed glass is encapsulated with RIM.

   Remove the fixed glass.
   Use special service tool: Power Fixed Glass Removal Tool.
   Use general equipment: Cold Knife.
   Use general equipment: Knife.
4. 4
   
   
   

   NOTICE: The new or used fixed glass must be installed within 2 hours after the urethane adhesive is cut. The exposed cut surfaces of the urethane oxidize and become inactive within 2 hours, reducing the effectiveness of the repair bond.

   Prepare the pinch weld area for installation of the new or used fixed glass.
   

   1. Trim or shave the original urethane adhesive on the pinch weld flange and on the glass (if reused) using a utility knife, leaving a base of 1 to 2 mm (0.04 to 0.08 in) on the surfaces, only when final installation will occur within 2 hours.

   2. Remove any foreign material or dirt from the pinch weld using a soft brush or vacuum cleaner.
      Use general equipment: Vacuum Cleaner.
5. 5
   If the paint layer has been damaged at the pinch weld to the point of penetrating to bare metal, apply primer only to these areas.
   Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207.
6. 6
   Apply primer as necessary.
   

   1. Apply primer only to the areas that were previously primed.
      Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207.

   2. If the clear coat layer has been damaged at the pinch weld without reaching bare metal, apply primer to these areas only.
      Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207.

Vehicles with Encapsulated RIM Glass

1. 1
   Clean the inside surface of the rear glass encapsulation RIM surface with an alcohol-free cleaner, making sure the ceramic-coated area is clean. Allow five minutes to dry.
2. 2
   
   
   Apply primer to the encapsulation RIM in accordance with the new fixed glass manufacturer's instructions. Allow at least 10 minutes to dry.
   Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207.
3. 3
   
   
   Cut the tip of the urethane adhesive applicator to the specified size.
   Material: Sika Tack® MOVE.IT

   

4. 4
   
   
   

   NOTICE: Make sure the urethane bead is uniform to prevent air and water leaks.

   Apply a bead of urethane adhesive.
   

   1. Start and finish at the overlap starting points to prevent air and water leaks.

   2. Apply a 14 mm (0.551 in) high and 8 mm (0.314 in) wide bead of urethane adhesive over the existing trimmed urethane adhesive bead on the weld flange.
      Use common equipment: Power Caulk Gun
      Material: Sika Tack® MOVE.IT

   3. Make sure there are no gaps in the bead.

   

Vehicles without encapsulated RIM glass

1. 1
   Clean the inside surface of the new fixed glass with glass cleaner.
   Material: Motorcraft® Ultra-Clear Glass Cleaner Spray / ZC-23 (ESR-M14P5-A)
2. 2
   
   
   Apply primer in accordance with the manufacturer's instructions for the new fixed glass. Allow to dry for a minimum of 10 minutes.
   Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207.
3. 3
   Visually inspect and remove residual urethane adhesive from the glass, leaving a thin layer to bond with the new urethane adhesive bead.
4. 4
   
   
   Apply primer in accordance with the manufacturer's instructions to the fixed glass wherever urethane adhesive was completely removed. Allow to dry for a minimum of 10 minutes.
   Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207.
5. 5
   
   
   Cut the tip of the urethane adhesive applicator to the specified size.
   Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express
   Material: Sika Tack ASAP urethane adhesive.

   

6. 6
   
   
   

   NOTICE: Make sure the urethane bead is uniform to prevent air and water leaks.

   Apply a bead of urethane adhesive.
   

   1. Start and finish at the overlap starting points to prevent air and water leaks.

   2. Apply a 14 mm (0.551 in) high and 8 mm (0.314 in) wide bead of urethane adhesive over the existing trimmed urethane adhesive bead on the weld flange.
      Use common equipment: Power Caulk Gun
      Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express
      Material: Sika Tack ASAP urethane adhesive.

   3. Make sure there are no gaps in the bead.

   

All vehicles

1. 1

   NOTICE: Door windows must remain open during adhesive curing.

   Open the vehicle windows to prevent air pressure from closing the doors from disturbing the urethane adhesive bond.
2. 2
   
   
   Install the fixed glass on the vehicle.
   

   1. Install the fixed glass, pressing it firmly by hand to ensure good contact.

   2. Secure the fixed glass in the correct position with tape until the urethane adhesive has cured.
3. 3
   If necessary, remove excess uncured urethane adhesive from the inside and outside surfaces of the fixed glass.
   Material: Motorcraft® Ultra-Clear Glass Cleaner Spray / ZC-23 (ESR-M14P5-A)
4. 4
   If necessary, install all removed components.
5. 5
   If equipped, perform the IPMA (Image Processing Module A) camera alignment.
   REFER TO: Lane Keeping System Operation and Component Description (419-07 Lane Keeping System, Description and Operation).