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Rear Quarter Window Glass - 4-Door > < Rear Door Window Glass

Focus 1999 (08.1998-12.2004)

Glass, Frames and Mechanisms - Rear Quarter Window Glass—3-Door Focus 1999 (08/1998-12/2004)
Removal and Installation

General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing adhesive oven
Glazing suction cups

Removal
  1. Remove the polyurethane (PU) adhesive cap and heat the PU adhesive for a minimum of 30 minutes.

  1. Detach the door opening weatherstrip from the B-pillar.

  1. Detach the rear lamp assembly from the C-pillar.

  1. Remove the rear lamp assembly.
    • Disconnect the electrical connector.

  1. Remove the safety belt trim panel.

  1. WARNING:
    WARNING:Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. When using the cutter wear ear protectors. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels.
    NOTE:
    NOTE:Some resistance may be encountered when cutting through the glass locating pegs in the lower corners of the glass.
    Using a suitable direct glazing cutter, cut the PU adhesive and, with the aid of another technician, use glazing suction cups to remove the glass.
    • Cut the PU adhesive from inside the vehicle to the given maximum depths.
    1. 20 mm
    1. 60 mm
    1. 75 mm
    1. 90 mm

Installation

  1. Carefully remove the remaining part of the glass locating pegs from the rear quarter window glass flange.

  1. CAUTION:
    CAUTION:Do not touch the adhesive surface as re-bonding will be impaired.
    Carefully trim the remaining PU adhesive from the rear quarter window glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the flange.
  1. Check the rear quarter window glass flange for damaged sheet metal, rust or foreign material which may have caused, or may cause, glass breakage.
  1. CAUTION:
    CAUTION:To make sure that the PU adhesive cures, it is essential that all bonding surfaces are free of moisture.
    Using a hot air gun, apply warm air (25°C) to the rear quarter window glass flange and glass bond line to remove all traces of moisture.
  1. Prepare the glass, rear quarter window glass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit.

  1. NOTE:
    NOTE:Discard the first 100 mm of PU adhesive as this may have reduced working time.
    NOTE:
    NOTE:To avoid water leaks, any breakage in the continuous bead must be overlapped by 20 mm.
    Apply the PU adhesive in a continuous bead of between 8 and 10 mm in height to the rear quarter window glass flange along the bond line.

  1. With the aid of another technician, use glazing suction cups to install the rear quarter window glass.
    • Press firmly and evenly into position.
  1. CAUTION:
    CAUTION:During the curing period of the PU adhesive, the door windows must be left open to avoid a build up of pressure when the doors are opened and closed.
    Using suitable tape, secure the rear quarter window glass in the correct position until the PU adhesive has cured.

  1. If the ambient temperature falls below 10°C, use a hot air gun and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).

  1. Install the safety belt trim panel.

  1. Install the rear lamp assembly.
    • Connect the electrical connector.

  1. Attach the rear lamp assembly to the C-pillar.

  1. Attach the door opening weatherstrip to the B-pillar.

Rear Quarter Window Glass - 4-Door > < Rear Door Window Glass