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Front Door Glass Top Run > < Front Door Window Regulator and Motor

Transit 2006.5 (04.2006-)

Glass, Frames and Mechanisms - Windshield Glass Transit 2006.5 (04/2006-)
Removal and Installation

General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Mixing/applicator gun
Direct glazing adhesive oven
Glazing suction cups
Materials
Name
Specification
Windshield Adhesive Kit
WSK-M11P57-A1 

Removal

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

  1. CAUTION:
    CAUTION:Make sure that the windshield wiper motor is in the park position.
    Remove the windshield wiper arms, hood hinge covers and hood seal.

  1. Remove the cowl panel grille.

  1. Remove the A-pillar exterior trim panels.
    1. Detach the door aperture upper weatherstrip.
    1. Release the retaining clips.
  1. Lower the hood.

  1. Remove the passenger assist handle.
    • Lever open the covers to expose the bolts.

  1. Remove the A-pillar trim panels.

  1. Remove the sun visors.

  1. Remove the sun visor retaining clips.

  1. Detach the front interior lamps.

  1. Disconnect the electrical connectors and remove the front interior lamps.
Vehicles with manual dimming interior mirror
  1. Remove the manual dimming interior mirror.
    • Using a thin bladed screwdriver, release the retaining clip.
Vehicles with manual dimming interior mirror with rain sensor
  1. Remove the manual dimming interior mirror upper trim panel.
    1. Release the retaining clips
    1. Pull the manual dimming interior mirror upper trim panel rearwards.

  1. Remove the manual dimming interior mirror lower trim panel.
    1. Release the retaining clips.
    1. Pull the manual dimming interior mirror lower trim panel downwards.

  1. Remove the rain sensor.
    1. Disconnect the rain sensor electrical connector.
    1. Release the rain sensor retaining clips.

  1. Remove the manual dimming interior mirror.
    • Using a thin bladed screwdriver, release the retaining clip.
Vehicles with heated windshield
  1. Disconnect the heated windshield electrical connectors.
All vehicles
  1. Detach the leading edge of the front headliner and place two blocks of suitable material between the headliner and the roof panel to act as spacers.

  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 upper corners of the glass.
    NOTE:
    NOTE:Care must be taken when cutting in the area of the locating blocks along the lower edge of the windshield glass.
    From inside the vehicle, using a suitable direct glazing cutter for bonded glass, cut the PU adhesive to the given maximum depths.
    1. 20 mm.
    1. 35 mm.
    1. 50 mm.
  1. With the aid of another technician, use glazing suction cups to remove the windshield glass.

  1. Remove the windshield glass weatherstrip.

  1. Remove the windshield glass locating blocks.
    • Remove the rivets.

Installation

All vehicles
  1. Carefully remove the remaining part of the glass locating pegs from the windshield glass flange.

  1. CAUTION:
    CAUTION:Do not touch the adhesive surface as re-bonding will be impaired.
    NOTE:
    NOTE:Make sure the spacers located at the lower corners of the windshield glass flange are secure.
    Carefully trim the remaining PU adhesive from the windshield glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the flange.

  1. Install new windshield glass locating blocks.
  1. Check the windshield 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 windshield glass flange and glass bond line to remove all traces of moisture.
  1. Prepare the glass, windshield glass flange and trimmed PU adhesive in accordance with the instructions supplied with the adhesive kit.

  1. NOTE:
    NOTE:Discard the first 100 mm of PU adhesive as this may have a reduced working time.
    NOTE:
    NOTE:To avoid water leaks, any breakage in the continuous bead should be overlapped by 20 mm.
    Using the mixing/applicator gun, apply a thin continuous bead of PU adhesive to the edge of the windshield glass.

  1. Install the windshield glass weatherstrip.

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

  1. With the aid of another technician, use glazing suction cups.
    • 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 open and closed.
    Using suitable tape, secure the windshield 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).
Vehicles with manual dimming interior mirror with rain sensor
  1. Install the manual dimming interior mirror.

  1. Install the rain sensor.
    1. Locate the rain sensor in the rain sensor mounting bracket.
    1. Push in the rain sensor retaining clips.
    1. Connect the rain sensor electrical connector.

  1. Install the manual dimming interior mirror lower trim panel.

  1. Install the manual dimming interior mirror upper trim panel.
Vehicles with manual dimming interior mirror
  1. Install the interior mirror.
Vehicles with heated windshield
  1. Connect the heated windshield electrical connectors.
All vehicles
  1. Remove the spacers and attach the leading edge of the front headliner to the roof panel.

  1. Connect the electrical connectors and install the front interior lamps.

  1. Install the sun visors.

  1. Install the sun visor retaining clips.
  1. Install the A-pillar trim panels.

  1. Install the passenger assist handle.
  1. Raise the hood.

  1. NOTE:
    NOTE:To eliminate wind noise, apply an additional bead of PU adhesive to the top corners of the windshield.
    Apply an additional bead of PU adhesive to the top corners of the windshield.

  1. Install the A-pillar exterior trim panels.
    1. Locate the retaining clips.
    1. Attach the door aperture upper weatherstrip.

  1. Install the cowl panel grille.

  1. Install the windshield wiper arms, hood hinge covers and hood seal.

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