Ford Workshop Service and Repair Manuals

Interior Auto Glass Cut-Out Knife Kit

164-R2450 or equivalent

1. 

   WARNING:Safety glasses and gloves must be worn when carrying out this procedure. Failure to follow these instructions may result in personal injury.
   Disconnect the two rear window defrost electrical connectors.

2. Remove the wiper motor. For additional information, refer to Section  501-16 Wipers and Washers.

3. Remove the high mounted stoplamp. For additional information, refer to Section  417-01 Exterior Lighting.

4. 

   CAUTION:Use care to avoid damage to the rear package trim cover panel.
   Using the special tool, cut the adhesive. Refer to the manufacturer instructions when using the tool.

5. Remove the liftgate door glass using a suitable suction tool.

6. 

   NOTE:To avoid rust formation, take extreme care not to scratch or otherwise damage the pinch weld.
   Inspect the pinch weld for damaged metal, rust or foreign objects. Repair the pinch weld as necessary.

1. 

   NOTE:A minimum of ten minutes is required for the primer surface to dry.
   Use a wool applicator to apply the urethane metal primer to any exposed areas on the rear window pinch weld.

2. Dry fit the replacement glass to the body.
   • Place the liftgate door window glass on the existing bed of urethane on the pinch weld.
   • Center the liftgate door window glass in the window opening.
   • Mark the liftgate door window glass alignment on the glass and the body with tape or a marking pencil.

3. 

   NOTE:When completed, the surface should be smooth and free of cuts and contamination.
   Trim any remaining urethane on the pinch weld to within 1 mm (0.04 inch) and 2 mm (0.08 in).

4. Place the liftgate door window glass on a stable work surface.

5. Clean the liftgate door window glass with an alcohol-free window cleaner.

6. 

   NOTE:Two applications of the urethane glass prep must be applied.
   

   NOTE:Wipe off the urethane glass prep WSB-M5B280-C2 or equivalent immediately after application because it flash dries.
   Using a clean, wool applicator, wipe the interior glass edge with urethane glass prep WSB-M5B280-C2 or equivalent 25 mm (1 inch) around the top, bottom and sides. Repeat the application.

7. Thoroughly shake and stir the urethane glass primer WSB-M2G314-B or equivalent to make sure of uniform pigmentation.

8. 

   NOTE:Allow a minimum of five minutes for the glass primer to dry.
   Use a clean, wool applicator to apply primer to the top, bottom and sides of the glass edge.

9. 

   NOTE:Leave a window slightly opened until the adhesive is cured.
   

   NOTE:Apply the new urethane on top of the existing material on the pinch weld. The bead should be triangular in shape.
   Apply an even bead of urethane adhesive WSB-M2G316-B or equivalent 16 mm (0.64 inch) high and 8 mm (0.32 inch) at base around the entire of sheet metal pinch weld.

10. 

    CAUTION:When replacing urethane-installed glass parts, the vehicle should not be driven until the urethane has cured. At 21° C, (70° F) and relative humidities above fifty percent, adequate cure time is typically twenty-four hours (less at higher temperatures and higher humidities). See detailed instructions provided by the urethane manufacturer. Inadequate or improper curing can adversely affect the retention of the liftgate door window glass.
    Install the liftgate door window glass on the pinch weld.
    • Align the liftgate door window glass using the alignment marks.
    • Install the liftgate door window glass on the pinch weld.

11. Inspect the liftgate door window glass for air or water leaks through the urethane seal.

12. Install the high mounted stop lamp. For additional information, refer to Section  417-01 Exterior Lighting.

13. Install the wiper motor. For additional information, refer to Section  501-16 Wipers and Washers.

14. Connect the two rear window defrost electrical connectors.