Glass, Frames & Mechanisms Ford Explorer Sport Trac I

GENERAL SPECIFICATION

General Specifications

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The windshield consists of

1. Standard plastic and glass laminate safety glass.
2. A window opening flange bonded with urethane adhesive.

The liftgate window (Sport) consists of

1. A standard plastic and glass laminate safety glass.
2. Heated window grid.
3. Two liftgate window glass hinges.
4. Two liftgate lifting cylinder anchors.

The fixed rear window (Sport Trac) consists of

1. A standard plastic and glass laminate safety glass.
2. A window opening flange bonded with foam butyl sealant and studs with nuts.

The power rear window (Sport Trac) consists of

1. A standard plastic and glass laminate safety glass.
2. A window control switch.
3. A window regulator.
4. A window motor.

The front door window consists of

1. A standard plastic and glass laminate safety glass.
2. A window control switch.
3. A window regulator.
4. A window regulator motor.

The rear door window (Sport Trac) consists of

1. A standard plastic and glass laminate safety glass.
2. A window control switch.
3. A window regulator.
4. A window regulator motor.

The rear quarter window (Sport) consists of

1. A standard plastic and glass laminate safety glass.
2. A window opening flange bonded with foam butyl sealant and studs with nuts.

The movable rear quarter window (Sport) consists of

1. A standard plastic and glass laminate safety glass.
2. An adjustable latch assembly.
3. A one piece seal attached to the pinch weld.
4. Two movable rear quarter window hinges.

The window control switch

1. Is located on each door trim panel.
2. May be used to raise or lower both passenger side and driver side windows from the master control on the driver door.
3. Includes a window lock feature that is controlled through the master control.
4. Can manually lower the driver side window when the master control is depressed longer than 0.4 second.

The power rear window control switch

1. Is located in the instrument panel center finish panel.
2. Will move the power rear window glass to one of three preset positions: fully open, fully closed and vent.

Wiring Diagrams

For Explorer Sport glass, frames and mechanisms wiring diagrams, see POWER WINDOWS in SYSTEM WIRING DIAGRAMS article. For Explorer Sport Trac glass, frames and mechanisms wiring diagrams, see POWER WINDOWS in SYSTEM WIRING DIAGRAMS article.

Scheme 1

Features & Operation

The generic electronic module (GEM) controls the opening of the LH driver side power window (window down motion) by activating the one-touch down (OTD) window relay. The one-touch down feature is a GEM only function.

1. The driver side window has two downward motions: manual mode and auto mode. The down window mode is selected by pressing the driver window control switch (driver control). When the GEM detects that the driver window control switch has been pressed for a time greater than 0.4 second, it enters the manual mode. If the GEM detects that the driver window control switch was depressed between 0.04 and 0.4 second, it enters the auto mode. (The ignition switch is in the RUN or ACC position).

Auto Mode

Auto mode will be terminated when any of the follow conditions are met

1. The LH window control switch is pushed to the up position or down position.
2. Seven seconds have elapsed since auto mode was initiated.
3. A window regulator motor stall condition is detected on the OTD sense line inputs.

One-Touch Down Relay

The GEM controls manual down and OTD window movement with the OTD relay for the LF window only.

The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal.

Power Rear Window

Note. The power rear window motor is not on the multiplex link. Any diagnosis and testing carried out on the power rear window will not involve the GEM module.

The power rear window motor is a 8-pin motor with integral electronics. The power rear window control switch is located on the instrument panel adjacent to the radio and provides a ground signal to the motor to signal an open, close or vent request. The integral electronics on the motor allow the power rear window to be moved to three positions: fully open, fully closed and vent (approximately two inches down from fully closed). The control switch is rotated clockwise and released to fully close the window, rotated counterclockwise and released to fully open the window, and pushed and released to actuate the window to the vent position.

The power rear window motor plastic pinion gear is mated to the drum housing of a single rail drum and cable window regulator. The motor is attached to the plastic drum housing by three screws. The motor uses internal Hall effect sensor feedback coupled to the microprocessor, to determine window position and operate the power rear window. If the microprocessor is not receiving the Hall effect sensor pulses, the motor will run for approximately half a second, then enter error mode (window will become inoperative). The motor contains a thermal breaker to protect the motor windings from over-current/over-temperature operation. Continued successive operation of the motor will cause the thermal breaker to open, causing a loss of power until the power rear window motor cools.

The power rear window motor operates with the ignition switch in the RUN/ACC position only and is sensed by the RUN/ACC and logic ground inputs. The motor is supplied with battery power and draws a key off load of approximately 1 mA. All of the high current required to move the window is supplied through the battery and motor ground inputs. The loss of either logic or motor ground will cause this system to become inoperative. For correct functionality, both power feeds and both ground feeds must be intact at the power rear window motor.

If a down or vent command is selected while the ignition switch is in the RUN/ACC position, and the ignition switch is turned to OFF or START, the window will move to the fully open or vent position and stop. If an up command is selected while the ignition switch is in the RUN/ACC position, and the ignition switch is turned to OFF or START, the window will stop if it is between vent and fully closed, or will move to the vent position and stop if it is between vent and fully open.

If an obstacle is detected in the power rear window opening as the window is closing upward, the window will automatically reverse direction and move toward the fully open position. This is known as "bounce-back". If, during a bounce-back condition, the power rear window control switch is released, then held in the up direction for at least two seconds, the window will travel up with no bounce-back protection (security override). If the ignition switch is turned to OFF or START, the window will reverse direction with bounce-back re-enabled. Ice, contaminant buildup, and environmentally induced tight spots in the window seals are all possible uses for the security override feature.

If power (B+) is disconnected from the power rear window motor while the window is in motion, the motor will enter position recovery mode when power is restored. Position recovery mode allows up and down movement of window in 15 mm (0.6 in) increments until the motor stalls the window glass in the upper header seal. If no internal or external faults exist, the motor will automatically resume normal operation.

The power rear window control switch is supplied with illumination ground inputs used to illuminate the control switch when the headlamp switch is turned to the PARK or ON position. These switch inputs do not affect operation of the window. The control switch uses the main ground input which is transferred to the open, closed, or vent outputs by closing a switch contact. If the main ground signal is missing, the window will become inoperative.

If the power rear window control switch, or its associated wiring, develops an open circuit, that function will become inoperative. If the open contact or associated wiring develops an open circuit, the window will only travel to the vent or fully closed positions. If the close contact or associated wiring develops an open circuit, the window will only travel to the fully open or vent positions. If the vent contact or associated wiring develops an open circuit, the window will only travel to the fully open or closed positions.

The power rear window motor will suspend normal operation if a power rear window control switch error exists. A control switch error is defined as open and close, open and vent, close and vent, or open, close and vent energized at the same time. The window will be inoperative if a control switch error is present.

If the motor is removed from the window regulator drum housing, or if a new motor is installed, the window must be initialized. A new motor will be in error mode and inoperative until initialized. Refer to REAR WINDOW MOTOR INITIALIZATION . For positioning the window regulator for glass removal/installation, refer to REAR WINDOW POSITIONING .

The power rear window will automatically adjust to system changes throughout its life. Changes in seal drag and slight changes in the fully closed position will occur and are automatically compensated for. Once initialized, the motor will soft stall into the upper and lower positions, contributing to the extended durability of the system.

Scheme 2

1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the scan tool tester does not power up, refer to the scan tool manufacturer's manual.
5. Carry out the DATA LINK DIAGNOSTICS test (except on power rear window for Sport Trac). If the scan tool responds with: CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/i-2000-2005/remont/communication-devices/#module-communications-network) article. NO RESP/NOT EQUIP for Generic Electronic Module (GEM), refer to «MULTIFUNCTION ELECTRONIC CONTROL MODULES»(/ford/explorer-sport-trac/i-2000-2005/remont/communication-devices/#multifunction-electronic-control-modules) article. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out the self-test diagnostics for the GEM.
6. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTCs) Index to continue diagnostics. See «GEM DIAGNOSTIC TROUBLE CODE (DTCS) INDEX»(/ford/explorer-sport-trac/i-2000-2005/remont/windows/#glass-frames-mechanisms__gem-diagnostic-trouble-code-dtcs-index) .
7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See «SYMPTOM CHART»(/ford/explorer-sport-trac/i-2000-2005/remont/windows/#glass-frames-mechanisms__symptom-chart) .
8. If the DTCs are retrieved that are not found in the following GEM Diagnostic Trouble Code (DTCs) Index, refer to «DIAGNOSTIC TROUBLE CODE CHART»(/ford/explorer-sport-trac/i-2000-2005/remont/communication-devices/#multifunction-electronic-control-modules__diagnostic-trouble-code-chart) in MULTIFUNCTION ELECTRONIC CONTROL MODULES article.

GEM Diagnostic Trouble Code (DTCs) Index

GEM DIAGNOSTIC TROUBLE CODE (DTCS) INDEX

Symptom Chart

SYMPTOM CHART

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Pinpoint Test K: The Power Rear Window Is Inoperative - Explorer Sport Trac Only

Note. The power rear window motor is not on the multiplex link. Any diagnosis and testing carried out on the power rear window will not involve the GEM module.

Note. This procedure must be carried out when repairs are performed on any part of the power rear window system including when the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window module is installed, and any operation in which grease or lubricants are applied to the power rear window system.

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REAR WINDOW MOTOR INITIALIZATION

Note. This procedure must be carried out when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window module is installed, and any operation in which grease or lubricants are applied to the power rear window system.

Note. All power rear window components (window glass module, window regulator, window motor, and glass runs) must be installed and torqued to specification before carrying out this procedure.

Note. Steps 1-6 must be completed within 30 seconds. The entire procedure must be completed within five minutes.

Note. Once the ignition key is turned to the ON position in Step 6, it must remain on until the entire procedure is completed.

Note. Steps 7 and 9 require that the power rear window control switch be held in the closed position until the power rear window motor stalls the window in the upper header seal. Step 8 requires that the window control switch be momentarily turned to the open position. Start with the ignition in the OFF position. Turn the ignition to the ON position. Press the power rear window control switch vent button six times. Turn the ignition to the OFF position. Press the power rear window control switch vent button six times. Turn the ignition to the ON position. The power rear window will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates that the power rear window motor has entered initialized mode. Rotate and hold the power rear window control switch to the closed position until the window stalls in the upper header seal. Momentarily rotate the power rear window control switch to the open position and release. The power rear window will carry out a one-touch down operation until the window stalls at the bottom of the travel stop designed into the window regulator. Rotate and hold the power rear window control switch to the closed position until the window stalls into the upper header seal. Once this operation is complete, the window will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates that the power rear window motor has been successfully initialized. Verify correct operation of the power rear window by moving the window to the fully open, vent, then fully closed positions.

REAR WINDOW POSITIONING

Note. Because the power rear window removal/installation position is approximately three-quarters down and the power rear window motor can only move the window to three positions, a special procedure is necessary to position the window to the removal/installation position.

Note. If the power rear window motor does not respond to this procedure, refer to the DIAGNOSIS & TESTING for repair. If the window must be removed and the window motor does not respond to this procedure, remove the window motor. The window then can be moved by carefully applying hand pressure in the downward direction.

Note. By only partially performing the power rear window motor initialization procedure, the window motor will enter error mode. In error mode, no window motor movement is possible and the window motor will have to be re-initialized. Refer to REAR WINDOW MOTOR INITIALIZATION .

Note. Steps 1-6 must be completed within 30 seconds. Start with the ignition in the OFF position. Turn the ignition to the ON position. Press the power rear window control switch vent button six times. Turn the ignition to the OFF position. Press the power rear window control switch vent button six times. Turn the ignition to the ON position. The power rear window will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates that the window motor has entered initialized mode. Rotate and hold the power rear window control switch to the closed position until the window stalls in the upper header seal. Momentarily rotate the power rear window control switch to the open position and release. The window will carry out a one-touch down operation until the window stalls at the bottom of the travel stop designed into the window regulator. Rotate and hold the power rear window control switch to the closed position momentarily until the window regulator glass attach nuts are lined up with the sheet metal access holes. The window will be approximately in the three-quarter down position when installed to the window regulator. Repeat this procedure if the window regulator glass attach nuts are raised too far above the sheet metal access holes.

Scheme 80

Note. Any breaks longer than 25 mm (1 inch) in one grid cannot be repaired. New back window glass must be installed. Breaks equal to or shorter than 25 mm (1 inch) the heated back window grid wire can be successfully repaired by using the following procedure. Obtain the following repair kit: Repair Kit Order Number 50-25-0584-0029. The vehicle should be allowed to reach 16°C (60°F) or above. Clean the repair area with denatured alcohol. Place the grid line mask over the break aligning the cut-out slots on either side of the repair area. Apply the epoxy to the repair area. Remove the mask without disturbing the epoxy. Use the special tool to heat the repair area for 1 to 2 minutes at a distance of about 25-50 mm (1-2 inches). This procedure should heat the repair area to approximately 149°C (300°F). The heated back window may be energized immediately after the repair. Optimum hardness and adhesion will occur after 24 hours. Do not disturb the repair area until that time.

Scheme 81

1. Obtain the following repair kit: Repair Kit Order Number 50-25-0584-0029.
2. The vehicle should be allowed to reach 16°C (60°F) or above.
3. Clean the area with denatured alcohol.
4. Apply the epoxy to the repair area.
5. Hold the terminal in place on the bus bar with an appropriate tool.
6. Apply epoxy to the repair area.

Removal & Installation

Note. Driver window control switch shown, all others are similar.

Front door

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1. Remove the front door trim panel.
2. Remove the front door belt line moulding. Remove the nut. Remove the moulding.
3. Remove the interior glass weatherstrip.
4. Remove the front door window glass rivets.
5. Remove the front door window glass through the outboard side of the front door.
6. To install, reverse the removal procedure. Use the special tool to install the rivets.

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1. Remove the rear door trim panel.
2. Remove the interior glass weatherstrip.
3. Remove the rear door belt line moulding nut.
4. Remove the rear door belt line moulding.
5. Position aside the water shield.
6. Connect the power window switch.
7. Remove the rear door window glass rivets. Lower the glass approximately two-inches to access the rivets through the holes.
8. Carefully lower the window regulator while holding the glass. Lower the glass.
9. Separate the front of the window run/weatherstrip from the door.
10. Remove the rear door window glass through the outboard side of the rear door.
11. To install, reverse the removal procedure. Use the special tool to install the rivets.

Scheme 92

1. Remove the quarter trim panel.
2. Remove the quarter window glass. Remove the nuts. Remove the quarter window glass.
3. To install, reverse the removal procedure. If the seal requires adjustment, disconnect the quarter window latch from the quarter trim panel. Rotate the quarter window latch clockwise to increase seal pressure or counterclockwise to reduce seal pressure.

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1. Remove the quarter trim panel.
2. Remove the rear quarter window glass. Remove the nuts. Push the rear quarter window glass outward to release the butyl seal.
3. Remove the excess foam butyl from the window opening.

Installation

1. Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. Start at the bottom middle and work around the frame.
2. Install the rear quarter window glass. Position the rear quarter window glass. Tighten the nuts.
3. Install the quarter trim panel.

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1. Fold down the rear seat backs.
2. Fold the loadspace trim panels up and remove the luggage compartment lower screws and loadspace trim panel.
3. Remove the pin-type retainers from the luggage compartment trim panel.
4. Open the luggage compartment trim panel access doors and remove the four pin-type retainers and the luggage compartment trim panel.
5. Remove the spare tire and jack assembly.
6. Remove the roof trim panel.
7. Remove the C-pillar safety belt guide bolts and position the safety belt guides aside.
8. Remove the pin-type retainer and position the C-pillar trim panels aside.
9. Remove the carpet pin-type retainers and pull the carpet back.
10. Position the rear window glass regulator access panel aside. Remove the screws. Remove the nut. Position the rear window glass regulator access panel aside.
11. Position the rear window glass to the 3/4 down position. For additional information, refer to «REAR WINDOW POSITIONING»(/ford/explorer-sport-trac/i-2000-2005/remont/windows/#glass-frames-mechanisms__rear-window-positioning) .
12. Remove the rear window weatherstrip moulding.
13. Remove the rear window glass bolts.
14. Secure the rear window glass in the full up position.
15. Remove the 12 rear window glass module nuts.
16. Push the rear window glass module out at the top.
17. Lift the rear window glass module from the rear of the cab to disengage the locating clip.
18. Remove the excess foam butyl from the window opening.
19. If necessary, remove the center rear window glass from the module.
20. To install, reverse the removal procedure. Apply 6 mm (0.23 in) foam butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear window glass module. Start at the bottom and work around the module.
21. Re-initialize the rear window glass motor. For additional information, refer to «REAR WINDOW MOTOR INITIALIZATION»(/ford/explorer-sport-trac/i-2000-2005/remont/windows/#glass-frames-mechanisms__rear-window-motor-initialization) .

Scheme 107

1. Remove the C-pillar trim panel.
2. Remove the 15 rear window glass nuts and remove the rear window glass.
3. Remove the excess foam butyl from the window opening.
4. To install, reverse the removal procedure. Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear window glass. Start at the bottom middle and work around the window opening.

Note. The power rear window motor can be removed and a new one installed without removing the seat or trim panel.

Note. When the power rear window motor is removed and installed, the motor must be initialized. For additional information, refer to REAR WINDOW POSITIONING .

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1. Fold down the passenger rear seat back.
2. Open the luggage compartment trim panel access door.
3. Remove the spare tire jack and handle assembly.
4. Position the carpet aside and position the water shield back from the rear window glass motor to access bolts.
5. Remove the rear window motor. Disconnect the electrical connector. Remove the bolts. Remove the rear window glass motor.
6. To install, reverse the removal procedure.

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1. Fold down the rear seat backs.
2. Fold the loadspace trim panels up and remove the luggage compartment lower screws and loadspace trim panel.
3. Remove the pin-type retainers from the luggage compartment trim panel.
4. Open the luggage compartment trim panel access doors and remove the four pin-type retainers and the luggage compartment trim panel.
5. Remove the spare tire jack and handle assembly.
6. Remove the carpet pin-type retainers and pull the carpet back.
7. Remove the water shield from the rear window glass motor.
8. Position the rear window glass regulator access panel aside. Remove the screws. Remove the nut. Position the rear window glass regulator access panel aside.
9. Position the rear window glass to the 3/4 down position. For additional information, refer to «REAR WINDOW POSITIONING»(/ford/explorer-sport-trac/i-2000-2005/remont/windows/#glass-frames-mechanisms__rear-window-positioning) .
10. Disconnect the rear window glass regulator motor electrical connector.
11. Remove the rear window glass bolts.
12. Secure the rear window glass in the full closed position.
13. Remove the upper rear window glass regulator bolts.
14. Loosen the right and lower rear window glass regulator drum housing bolts, and remove the left rear window glass regulator drum housing bolt.
15. Remove the rear window glass regulator assembly. Position the slider to the midway point.
16. If necessary, transfer the rear window glass motor.
17. To install, reverse the removal procedure.

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1. Open the liftgate glass.
2. Remove the two heated rear window electrical connector covers.
3. Disconnect the two heated rear window electrical connectors.
4. Remove the two liftgate lifting cylinder pins.
5. Remove the liftgate window glass. Position the liftgate trim panel aside. Remove the access the covers and the liftgate window hinge nuts.
6. Remove the liftgate window glass.
7. To install, reverse the removal procedure.

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1. Remove the front door trim panel.
2. Remove the front door speaker. Remove the screws. Disconnect the electrical connector. Remove the speaker.
3. Remove the water shield.
4. Disconnect the front door window regulator motor electrical connector.
5. Drill a 13 mm (0.52 in) hole using the locator in the door sheet metal as a guide.
6. Remove the bolts and the front door window regulator motor.
7. To install, reverse the removal procedure. Cycle the door glass to make sure of engagement of the drive mechanism.

Scheme 126

1. Remove the rear door window regulator. For additional information, refer to «REAR DOOR WINDOW REGULATOR»(/ford/explorer-sport-trac/i-2000-2005/remont/windows/#glass-frames-mechanisms) .
2. Remove the rear door window regulator motor. Remove the bolts. Remove the rear door window regulator motor.
3. To install, reverse the removal procedure. Cycle the door glass to make sure of engagement of the drive mechanism.

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1. Raise the front door window glass to the full up position.
2. Remove the interior door handle. For additional information, refer to «INTERIOR DOOR HANDLE»(/ford/explorer-sport-trac/i-2000-2005/remont/door-locks-anti-theft-systems/#handles-locks-latches-entry-systems) in HANDLES, LOCKS, LATCHES & ENTRY SYSTEMS article.
3. Support the front door window glass.
4. Disconnect the front door window regulator motor electrical connector.
5. Remove the equalizer bracket nuts.
6. Remove the front door window regulator. Remove the rivets. Remove the nut.
7. Remove the front door window regulator motor. Remove the bolts. Remove the front door window regulator motor.
8. To install, reverse the removal procedure. Use the special tool to install the rivets. Cycle the door glass to make sure of engagement of the drive mechanism.

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1. Raise and support the rear door window glass to the full up position.
2. Remove the interior door handle. For additional information, refer to «INTERIOR DOOR HANDLE»(/ford/explorer-sport-trac/i-2000-2005/remont/door-locks-anti-theft-systems/#handles-locks-latches-entry-systems) in HANDLES, LOCKS, LATCHES & ENTRY SYSTEMS article.
3. Remove the rear door speaker. Remove the screws. Disconnect the electrical connector. Remove the speaker.
4. Remove the water shield.
5. Disconnect the rear door window regulator motor electrical connector.
6. Remove the rear door window regulator rivets.
7. Remove the rear door window regulator. Slide the regulator arms off of the window glass track.
8. To install, reverse the removal procedure. Use the special tool to install the rivets. Cycle the door glass to make sure of engagement of the drive mechanism.

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1. Remove the front door trim panel.
2. Remove the interior glass weather strip.
3. Position aside the water shield.
4. Remove the exterior rear view mirror. For additional information, refer to «EXTERIOR MIRROR»(/ford/explorer-sport-trac/i-2000-2005/remont/mirrors/#rear-view-mirrors) in REAR VIEW MIRRORS article.
5. Release the two pin-type retainers.
6. Remove the front door glass top run bolts.
7. Remove the front door glass top run.
8. To install, reverse the removal procedure.

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1. Remove the rear door window glass. For additional information, refer to «REAR DOOR WINDOW GLASS»(/ford/explorer-sport-trac/i-2000-2005/remont/windows/#glass-frames-mechanisms) .
2. Remove the rear door glass top run bolt.
3. Remove the door glass top run.
4. To install, reverse the removal procedure.

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Removal

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1. Remove the windshield side garnish mouldings.
2. Remove the interior rear view mirror.
3. Remove the overhead console.
4. Remove the sun visors. Remove the sun visor screws. Remove the sun visors. If equipped, disconnect the electrical connector.
5. Remove the sun visor clips. Remove the sun visor clip screws. Remove the sun visor clips.
6. Lower the front portion of the headliner.
7. Remove the cowl grille.
8. Remove the upper windshield weatherstrip.
9. Remove the LH and RH windshield mouldings.
10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
11. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and work toward the bottom corners.
12. Using the special tool, distance the windshield from the body.
13. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
14. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld.

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1. Dry fit the windshield. Make alignment marks with tape or non-staining grease pencil.
2. Trim the remaining urethane adhesive on the pinch weld to within the specification. The existing urethane adhesive surface should be smooth and free of cuts and contamination.
3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to ten minutes to dry.
4. Apply (A) Foam Dam meeting Ford specification WSB-M2G234-C to the (B) pinch weld.
5. If reinstalling original windshield, remove the excess urethane adhesive from the windshield glass.
6. Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic coated area is clean.
7. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be urethaned.
8. If installing a new windshield glass, apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the pervious step. Allow five minutes to dry.
9. Cut the urethane adhesive applicator tip to specification.
10. Apply a bead of urethane adhesive Essex 400-HV or Essex U-216, which meets Ford specification WSB-M2G316-B to the pinch weld just outside the foam dam.
11. Install the windshield glass aligning it to the marks previously made.
12. After the windshield glass is set, check for water leaks and add urethane adhesive where needed.
13. Install the upper windshield weatherstrip.
14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass.
15. Install the LH and RH windshield mouldings.
16. Install the cowl grille.
17. Install the overhead console.
18. Install the sun visor clips. Position the sun visor clips. Install the screws.
19. Install the sun visors. Position the sun visors. If equipped, connect the electrical connector. Install the screws.
20. Install the front portion of the headliner.
21. Install the interior rear view mirror.
22. Install the windshield side garnish mouldings.

See also:
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC CONTROL MODULES
• DIAGNOSTIC TROUBLE CODE CHART
• INTERIOR DOOR HANDLE
• EXTERIOR MIRROR
• REAR WINDOW MOTOR INITIALIZATION
• REAR WINDOW POSITIONING
• GEM DIAGNOSTIC TROUBLE CODE (DTCS) INDEX
• SYMPTOM CHART
• PINPOINT TEST A
• PINPOINT TEST K