Fixed Glass – General Procedures

Special Service Tools / General Equipment

Materials

Repair

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.

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

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

   2. Power Tool Method – Use various power tools from the vehicle interior with a cutting or oscillating blade.
      Use basic equipment: Power Fixed Glass Removal Tool.

   3. Piano Wire Method – Use piano wire to cut the urethane from inside and outside the vehicle with the help of an assistant.
      Use common equipment: glass cutting wire.
2. 2
   When using the cold knife method, apply masking tape to protect the perimeter of the window opening from paint damage. Multiple layers of tape may be required.
3. 3
   
   
   

   NOTICE: New or used stationary glass must be installed within 2 hours of cutting the urethane adhesive. Exposed cut surfaces of urethane oxidize and become inactive within 2 hours, which reduces 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.

   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: New or used stationary glass must be installed within 2 hours of cutting the urethane adhesive. Exposed cut surfaces of urethane oxidize and become inactive within 2 hours, which reduces the effectiveness of the repair bond.

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

   1. Cut or shave the original urethane adhesive on the pinch weld flange and the glass (if reused) using a utility knife, leaving a base of 1 mm to 2 mm (0.04 in to 0.08 in) on the parts, only when the final installation is 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 location down 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 clearcoat layer has been damaged on the pinch weld but not down to bare metal, apply primer only to these areas.
      Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207.
7. 7
   Clean the inside surface of the new fixed glass with glass cleaner.
   Material: Motorcraft® Ultra-Clear Glass Cleaner Spray / ZC-23 (ESR-M14P5-A)
8. 8
   
   
   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.
9. 9
   Visually inspect and remove residual urethane adhesive from the glass, leaving a thin layer to bond with the new urethane adhesive bead.
10. 10
    
    
    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.
11. 11
    
    
    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.

    

12. 12
    
    
    

    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 urethane adhesive bead 14 mm (0.551 in) high and 8 mm (0.314 in) wide over the existing cut urethane on the pinch weld.
       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.

    

13. 13

    NOTICE: Door windows must remain open during adhesive curing.

    Open the vehicle windows to prevent air pressure from closing the doors and disturbing the urethane adhesive bond.
14. 14
    
    
    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.
15. 15
    If necessary, remove excess uncured urethane adhesive from the inner and outer surfaces of the stationary glass.
    Material: Motorcraft® Ultra-Clear Glass Cleaner Spray. / ZC-23 (ESR-M14P5-A)
16. 16
    If necessary, install all removed components.
17. 17
    If equipped, perform IPMA camera calibration.
    Refer to: Lane Keeping System - System Operation and Component Description (419-07 Lane Keeping System, Description and Operation).