Window and Glass Ford Five Hundred I

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Glass, Frames and Mechanisms

The glass, frames and mechanisms consist of the following

1. Window regulators
2. Door window regulator motors
3. Front door glass top run
4. Front door window glass
5. Liftgate window glass (Freestyle)
6. Rear door glass top run
7. Rear door window glass
8. Rear quarter glass
9. Rear window glass
10. Rear fixed window glass
11. Rear window regulator and motor - run and brackets
12. Window control switches
13. Accessory delay relay
14. Smart junction box (SJB)
15. Windshield glass
16. Heated rear window grid
17. Heated rear window grid relay

The glass, frames and mechanisms include the following

1. Standard plastic and laminate safety glass
2. Liftgate glass which houses the rear defrost grid and rear wiper arm (Freestyle)
3. Windshield glass which is bonded to the opening flange with a urethane sealant
4. Standard power windows which include one-touch up, one-touch down and lock-out feature (left front only)

The window regulator control switch

1. is located on each door trim panel.
2. may be used to raise or lower all windows from the left front window control switch, or the individual side window from the corresponding individual door switch.
3. can lock out passenger front and rear window control switches when the lock-out switch on the left front window control switch is turned on.
4. can manually lower the driver side window when the left front window control switch is pressed and held in the DOWN position.
5. can automatically lower the driver side window when the left front window control switch is momentarily pressed to the DOWN position and released.

Refer to POWER WINDOWS (Montego), POWER WINDOWS (Five Hundred) or POWER WINDOWS (Freestyle) for schematic and connector information.

Special Tool(s)

SPECIAL TOOL DESCRIPTION World Diagnostic System (WDS) Vehicle Communication Module (VCM), with appropriate adapters, or equivalent scan tool 73III Automotive Meter 105-R0057 or equivalent

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LH Front Power Window Control

The LH front window motor is an 8-pin motor with integral electronics, and must be initialized whenever a new window motor has been installed. When mechanical repairs have been carried out on the LH front window regulator or glass run, the LH front window motor must be de-initialized, and then initialized. The LH front window control switch sends 3 separate signals to the LH front window motor: UP, DOWN and AUTO. The LH front window control switch provides a 12-volt signal to the LH front window motor to request an up or down operation. When AUTO up or AUTO down is requested, the LH front window control switch provides a 12-volt signal on the up or down line and a ground signal on the AUTO line simultaneously. The up and down contacts are connected to ground and the AUTO contact is floating within the front window control switch when the switch is in the NEUTRAL position. The UP, DOWN and AUTO feeds to the LH front window motor are all low current.

The LH front window motor is splined to a nylon pinion drive gear inside a composite plastic housing, and the assembly is mounted to the drum housing of a dual rail drum and cable window regulator. The LH front window motor uses internal Hall-effect sensor feedback coupled to the internal microprocessor to determine window glass position and operate the window motor. If the Hall-effect pulses are not being received by the microprocessor, the LH front window motor will run for approximately 1/10 second each time the switch is pressed. The LH front motor contains a thermal breaker to protect the motor windings from overcurrent/overtemperature operation. Continued excessive operation of the LH front motor will cause the thermal breaker to open, causing a loss of function until the window motor cools.

The LH front window motor operates with the ignition switch in the RUN or ACCESSORY positions, or when the delayed accessory relay is active. The LH front motor is supplied with B+ power and draws a key-off load of approximately 3/4 mA. The high current required to move the window is supplied through the B+ and motor ground input. For the LH front motor to operate correctly, both power feeds and the ground feed must be intact at the LH front window motor.

The LH front window motor will not lose initialization if power (B+) is removed while the LH front window is not in motion. If power (B+) is disconnected from the LH front window motor while the window is in motion, the window motor will enter position recovery mode when power is restored (AUTO up will be disabled). Position recovery mode allows proportional up (and down) movement of the window until the LH front window motor stalls the window glass into the upper header seal. If no internal or external faults are present, the window motor will automatically resume normal (full) operation.

When the LH front window motor is operating in AUTO up or AUTO down mode, movement of the LH front window can be stopped by pressing the switch to any position (UP, DOWN, AUTO up, AUTO down). The LH front window control switch must be released before the window will move again.

The LH front window motor has a security override feature. If an obstacle has been detected in the window opening as the window glass is moving upward, the window motor will automatically reverse direction and move the glass toward the fully open position (in both proportional up and one-touch up modes). This is known as "bounce-back". Once the window motor stops the glass at its bounce-back position, and within 2 seconds the switch is released, then held in the AUTO up position, the window motor will move the glass up with no bounce-back protection (security override). If the switch is released before the window glass reaches the fully closed position, the window motor will stop with bounce-back automatically enabled for the next window up movement. If the ignition switch is turned to OFF or START (without delayed accessory), the window motor will stop. The only exception is when an obstacle is detected in the window opening while delayed accessory power is not present. In this case the window motor will bounce back, then stop. Ice, contaminant buildup, and environmentally induced tight spots in the LH front window seals are all possible conditions that will activate the security override feature. If an obstruction occurs between 4 mm (0.15 in) and 200 mm (7.87 in) of window opening, the bounce-back position will be 250 mm (9.84 in) of window opening. If an obstruction occurs at a position greater than 200 mm (7.87 in) of window opening, the bounce-back position will be 50 mm (1.96 in) below where the obstruction occurred.

The LH front window control switch has illumination and illumination ground inputs, which are used to illuminate the switch when the headlamp switch is turned to the PARK or ON position (the AUTOLAMP position may also energize this input). These switch inputs do not directly affect operation of the LH front window. The LH front window control switch uses the delayed accessory power input, which is transferred to the up or down outputs when the corresponding switch contact is closed. The LH front window control switch is grounded to the chassis through the main switch ground input, which is transferred to the AUTO output when the corresponding LH front window control switch contact is closed. If the delayed accessory feed to the front window control switch is missing, none of the windows will function. If the main ground signal is missing, the LF AUTO functions will be inoperative and the remaining three windows will also be inoperative.

If there is an open in the LH front window control switch or the associated wiring, the related function will become inoperative. If the UP contact of the switch or the associated wiring develops an open circuit, the LH front window will only operate in the down direction, or in the one-touch down mode. If the down contact of the switch or the associated wiring develops an open circuit, the LF window will only operate in the up direction, or in the one-touch up mode. If the auto contact of the switch or the associated wiring develops an open circuit, the LF window will only move proportionally up or down.

The LF window motor will not operate if a switch error exists. A switch error is defined as UP and DOWN, AUTO input without up or down, or up, down, and AUTO inputs energized at the same time. The LH front window will appear to be inoperative if a switch error is present.

A new LH front window motor will only operate in proportional up/down mode, and the bounce back feature will be disabled prior to initialization. If the switch is actuated to the AUTO up or AUTO down position and released, window movement will stop when the up or down contact in the LH front window control switch is released. If the LH front window motor is removed from the window regulator drum housing, or if a new LH front window motor is installed, it must be initialized. Refer to DOOR WINDOW MOTOR INITIALIZATION .

The LH front window motor will automatically adjust to system changes throughout its life: changes in seal drag and slight changes in the full open position will occur and will be automatically compensated for. Once initialized, the LH front window motor will soft stall into the upper and lower positions contributing to extended durability of the system. If the LH front window does not seal completely in the full up position (very small gaps/non bounce-back events only), the LH front window switch can be actuated to the proportional UP position and the LH front window will be energized for a fraction of a second to fully seal and this new position will be learned.

Passenger Window Operation

Passenger windows may be raised or lowered using the LH front window control switch or the corresponding passenger window control switch. Passenger window control switches receive power when the delayed accessory relay is active and the LH front window lock switch is in the unlock position. When the LH front window lock switch is in the lock position, the passenger windows will not operate.

Delayed Accessory Power

The smart junction box (SJB) controls power to the power windows, the audio system, and the power roof opening panel with the delayed accessory relay. The SJB activates the delayed accessory relay whenever the ignition switch is in the RUN or the ACCESSORY position, or when the ignition switch is changed from RUN or ACCESSORY to the OFF/LOCK position and the LH and RH front doors are closed.

The SJB will deactivate the delayed accessory feature when

1. the LF door is ajar and the ignition switch is in the off/lock or key-out position.
2. the RF door is ajar and the ignition switch is in the off/lock or key-out position.
3. 10 minutes have elapsed since the ignition switch was changed from ACC or RUN to the off/lock position.

Rear Window Defrost

The smart junction box (SJB) controls power to the heated backlight by controlling the state of the heated backlight relay. When the rear window defrost switch is pressed, the SJB will activate the heated backlight relay. When the heated backlight relay is active, the heated backlight will be energized.

The SJB will deactivate the heated backlight relay when one of the following conditions is met

1. The rear window defrost switch is pressed when the feature is active.
2. Ignition switch state is changed from RUN to off/lock.
3. The 17-minute timer completes.

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION Mechanical Electrical Door window regulator and motor Door glass run Door window glass Loose, corroded connectors Circuitry Window control switch Battery junction box (BJB) fuse(s) Smart junction box (SJB) fuse(s) SJB circuit breaker SJB heated backlight relay Delayed accessory relay Battery saver relay Heated backlight grid
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 cause is not visually evident, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: check that the program card is correctly installed. check the connections to the vehicle. check the ignition switch position.
5. If the scan tool still does not communicate with the vehicle, refer to the scan tool operating manual.
6. Carry out the data link diagnostics test using the scan tool. If the scan tool responds with: CAN circuit fault; all electronic control units no response/not equipped, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#module-communications-network-system) . No response/not equipped for SJB, go to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#multifunction-electronic-modules-system) . System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the SJB.
7. If the DTCs retrieved are related to the concern, go to the «SMART JUNCTION BOX (SJB) DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__smart-junction-box-sjb-diagnostic-trouble) .
8. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__symptom-chart) to continue the diagnostics.

Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index

SMART JUNCTION BOX DIAGNOSTIC TROUBLE CODE INDEX

For a complete list of SJB DTCs, refer to MULTIFUNCTION ELECTRONIC MODULES .

Symptom Chart

SYMPTOM

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Normal Operation

Under normal operation the LH front power window control switch receives power through circuit 1499 (PK/LG), which is the delayed accessory relay output from the smart junction. The delayed accessory relay is integral to the smart junction box (SJB). The LH front power window control switch is grounded to the chassis through circuit 1205 (BK).

Possible Causes

1. Circuit 1499 (PK/LG) open
2. Circuit 1205 (BK) open
3. LH front window control switch
4. SJB

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1. A1 CHECK CIRCUIT 1499 (PK/LG) FOR VOLTAGE Disconnect: LH Front Window Control Switch C504a. Key in ON position. Measure the voltage between LH front window control switch C504a-5, circuit 1499 (PK/LG), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A3 . No : GO to A2.
2. A2 CHECK CIRCUIT 1499 (PK/LG) FOR AN OPEN Key in OFF position. Disconnect: SJB C2280e. Measure the resistance between LH front window control switch C504a-1, circuit 1499 (PK/LG), harness side and SJB C2280e-4, circuit 1499 (PK/LG), harness side. Is the resistance less than 5 ohms? Yes : GO to «PINPOINT TEST H»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) to diagnose the delayed accessory relay circuit. No : REPAIR the circuit. TEST the system for normal operation.
3. A3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN Disconnect: LH Front Window Control Switch C504b. Measure the resistance between LH front window control switch C504b-4, circuit 1205 (BK), harness side and ground. Is the resistance less than 5 ohms? Yes : INSTALL a new LH front window control switch. REFER to «WINDOW CONTROL SWITCH»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.

Pinpoint Test B: A Single Power Window Is Inoperative - LH Front

Note. A new LH front power window motor will only operate in proportional up or down mode until initialized. Refer to DOOR WINDOW MOTOR INITIALIZATION .

Note. The LH front power window motor must be initialized whenever a new motor is installed.

Note. The LH front power window motor must be de-initialized, then initialized whenever the LH front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new window glass is installed, a new top run is installed, or for any operation in which grease or lubricants are applied to the window regulator or glass run.

Under normal operation the LH front power window control switch receives power from the delay accessory relay through circuit 1499 (PK/LG) and is grounded to chassis through circuit 1205 (BK). When the LH front window control switch is operated in the up position, the LH front window motor receives power through circuit 226 (WH/BK). When the LH front window control switch is operated in the down position, the LH front window motor receives power through circuit 227 (YE). When the LH front window motor receives a ground signal on circuit 2018 (OG/YE), the LH front window motor will enter one-touch up/down mode. The LH window motor receives battery power through circuit 995 (GY) at all times, and delayed accessory power through circuit 2086 (RD/LB) when the key is ON and the delayed accessory feature is active.

1. Inoperative LH front window motor
2. Inoperative LH front window control switch
3. LH front window motor not initialized
4. Open in circuits 226 (WH/BK), 227 (YE), 995 (GY), 1205 (BK), 1499 (PK/LG), or 2086 (RD/LB)

Note. A new LH front power window motor will only operate in proportional up or down mode until initialized. Refer to DOOR WINDOW MOTOR INITIALIZATION .

Note. The LH front power window motor must be initialized whenever a new motor is installed.

Note. The LH front power window motor must be de-initialized, then initialized whenever the LH front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new window glass is installed, a new top run is installed, or for any operation in which grease or lubricants are applied to the window regulator or glass run.

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1. B1 CHECK THE POWER TO THE WINDOW MOTOR Key in OFF position. Disconnect: LH Front Window Motor C524. Measure the voltage between LH front window motor C524-1, circuit 995 (GY), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to B2. No : REPAIR the circuit. DE-INITIALIZE, then INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation.
2. B2 CHECK THE LH FRONT WINDOW MOTOR DELAYED ACCESSORY FEED Key in ON position. Measure the voltage between LH front window motor C524-3, circuit 2086 (RD/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to B3. No : REPAIR the circuit. DE-INITIALIZE, then INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation.
3. B3 CHECK THE LH FRONT WINDOW MOTOR GROUND Key in OFF position. Measure the resistance between LH front window motor C524-4, circuit 1205 (BK), harness side and ground. Is the resistance less than 5 ohms? Yes : GO to B4. No : REPAIR the circuit. DE-INITIALIZE, then INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation.
4. B4 CHECK THE LH FRONT WINDOW CONTROL SWITCH-TO-LH FRONT WINDOW MOTOR FEEDS Disconnect: LH Front Window Control Switch C504b. Measure the resistance between LH front window motor C524-5, circuit 226 (WH/BK), harness side and LH front window control switch C504b-2, circuit 226 (WH/BK), harness side; and between LH front window motor C524-6, circuit 227 (YE), harness side and LH front window control switch C504b-6, circuit 227 (YE), harness side; between LH front window motor C524-2, circuit 2018 (OG/YE), harness side and LH front window control switch C504b-3, circuit 2018 (OG/YE), harness side. Are the resistances less than 5 ohms? Yes : GO to B5. No : REPAIR the circuit. DE-INITIALIZE, then INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation.
5. B5 CHECK THE LH FRONT WINDOW CONTROL SWITCH Carry out the LH front window control switch component test. Refer to «COMPONENT TESTING»(/ford/five-hundred/i-2004-2007/remont/accessories-control-systems/#component-testing) for component testing. Did the window control switch pass the component test? Yes : INSTALL a new LH front window motor. REFER to «GLASS, FRAMES AND MECHANISMS - EXPLODED VIEW, FRONT DOOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) and «WINDOW REGULATOR AND MOTOR - FRONT DOOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation. No : INSTALL a new LH front window control switch. REFER to «WINDOW CONTROL SWITCH»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation.

The RH front window control switch receives delayed accessory power through circuit 170 (RD/LB) when the window lock switch on the LH front window control switch is set to the unlock position, and the delayed accessory feature is active. When the RH front window control switch is pressed to the down position, the RH front window control switch receives ground from the LH front window switch through circuit 1505 (YE/RD). When operating the RH front window in the down direction, the RH front window control switch supplies power to the RH front window motor through circuit 333 (YE/RD), and ground through circuit 334 (RD/YE).

When the RH front window control switch is pressed to the up position, the RH front window control switch receives ground from the LH front window switch through circuit 1506 (RD/WH) When operating the RH front window in the up direction, the RH front window control switch provides power to the RH front window motor through circuit 334 (RD/YE) and ground through circuit 333 (YE/RD).

RH Front Window Operation From LH Front Switch

When the RH front power window is operated in the up direction from the LH front window control switch, power is sent to the RH front window control switch through circuit 1505 (YE/RD), which transfers power to the RH front window motor through circuit 334 (RD/YE). Ground is provided to the RH front window switch through circuit 1506 (RD/WH), which transfers ground to the RH front window motor through circuit 333 (YE/RD).

When the RH front power window is operated in the down direction from the LH front window control switch, power is sent to the RH front window control switch through circuit 1506 (RD/WH), which transfers power to the front window motor through circuit 333 (YE/RD). Ground is provided to the RH front window switch through circuit 1505 (YE/RD), which transfers ground to the RH front window motor through circuit 334 (RD/YE).

1. Circuit 170 (RD/LB) open
2. Circuit 1505 (YE/RD) open
3. Circuit 1506 (RD/WH) open
4. LH front window control switch
5. RH front window control switch
6. RH front window motor

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1. C1 CHECK THE RH FRONT POWER WINDOW MOTOR Disconnect: LH Front Window Control Switch C504a and C504b. Key in ON position. Connect a fused jumper wire between LH front window control switch C504b-1, circuit 1505 (YE/RD), harness side and LH front window control switch C504a-5, circuit 1499 (PK/LG), harness side. Connect a second fused jumper wire between LH front window control switch C504b-5, circuit 1506 (RD/WH) and LH front window control switch C504b-4, circuit 1205 (BK). The RH front window should operate in the UP direction. Connect a fused jumper wire between LH front window control switch C504b-5, circuit 1506 (RD/WH), harness side and LH front window control switch C504a-5, circuit 1499 (PK/LG), harness side. Connect a second fused jumper wire between LH front window control switch C504b-1, circuit 1505 (YE/RD) and LH front window control switch C504b-4, circuit 1205 (BK). The RH front window should operate in the DOWN direction. Does the RH front window operate correctly? Yes : GO to C2. No : GO to C4 .
2. C2 CHECK CIRCUIT 170 (RD/LB) FOR VOLTAGE Key in OFF position. Connect: LH Front Window Control Switch C504a and C504b. Disconnect: RH Front Window Control Switch C604. Key in ON position. NOTE: Be sure the window lock switch is set to the unlock position. Measure the voltage between RH front window control switch C604-5, circuit 170 (RD/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to C3. No : REPAIR the circuit. TEST the system for normal operation.
3. C3 CHECK THE LH FRONT WINDOW CONTROL SWITCH Key in OFF position. Disconnect: LH Front Window Control Switch. Carry out the LH front window control switch component test. Refer to «COMPONENT TESTING»(/ford/five-hundred/i-2004-2007/remont/accessories-control-systems/#component-testing) . Did the LH front window control switch pass the component test? Yes : GO to C4. No : INSTALL a new LH front window control switch. REFER to «WINDOW CONTROL SWITCH»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation.
4. C4 CHECK THE RH FRONT WINDOW CONTROL SWITCH Carry out the RH front window control switch test. Refer to «COMPONENT TESTING»(/ford/five-hundred/i-2004-2007/remont/accessories-control-systems/#component-testing) . Did the RH front window control switch pass the component test? Yes : GO to C5. No : INSTALL a new RH front window control switch. REFER to «WINDOW CONTROL SWITCH»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation.
5. C5 CHECK CIRCUITS 1505 (YE/RD) AND 1506 (RD/WH) FOR AN OPEN Measure the resistance between RH front window control switch C604-1, circuit 1505 (YE/RD), harness side, and LH front window control switch C504b-1, circuit 1505 (YE/RD), harness side. Measure the resistance between RH front window control switch C604-6, circuit 1506 (RD/WH), harness side, and LH front window control switch C504b-5, circuit 1506 (RD/WH), harness side. Are the resistances less than 5 ohms? Yes : GO to C6. No : REPAIR the circuit(s). TEST the system for normal operation.
6. C6 CHECK CIRCUIT 333 (YE/RD) AND CIRCUIT 334 (RD/YE) FOR AN OPEN Disconnect: RH Front Window Motor C608. Measure the resistance between RH front window control switch C604-3, circuit 333 (YE/RD), harness side and RH front window motor C608-1, circuit 333 (YE/RD), harness side. Measure the resistance between RH front window control switch C604-4, circuit 334 (RD/YE), harness side and RH front window motor C608-2, circuit 334 (RD/YE), harness side. Are both resistances less than 5 ohms? Yes : INSTALL a new RH front window motor. REFER to «GLASS, FRAMES AND MECHANISMS - EXPLODED VIEW, FRONT DOOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) and «WINDOW REGULATOR AND MOTOR - FRONT DOOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation. No : REPAIR the circuit(s). TEST the system for normal operation

The LH rear window control switch receives delayed accessory power from the LH front window control switch through circuit 170 (RD/LB) when the window lock switch is set to the unlock position, and the delayed accessory feature is active. When the LH rear window is operated in the up direction from the LH rear window control switch, power is sent to the LH rear window motor through circuit 884 (YE/BK), and ground through circuit 885 (YE/LB). When the LH rear window is operated in the down direction from the LH rear window control switch, power is sent to the LH rear window motor through circuit 885 (RD/LB), and ground through circuit 884 (YE/BK).

The RH rear window control switch receives delayed accessory power from the LH front window control switch through circuit 170 (RD/LB) when the window lock switch is set to the unlock position, and the delayed accessory feature is active. When the RH rear window is operated in the UP direction from the RH rear window control switch, power is sent to the RH rear window motor through circuit 882 (BN/YE), and ground through circuit 881 (BN). When the RH rear window is operated in the down direction from the RH rear window control switch, power is sent to the RH rear window motor through circuit 881 (BN), and ground through circuit 882 (BN/YE).

Rear Window Operation From LH Front Switch

When the LH rear power window is operated in the up direction from the LH front window control switch, power is sent to the LH rear window control switch through circuit 2015 (GY/BK), which transfers power to the LH rear window motor through circuit 884 (YE/BK). Ground is provided to the LH rear window switch through circuit 2014 (YE/LB), which transfers ground to the LH rear window motor through circuit 885 (YE/LB).

During LH rear power window down operation from the LH front window control switch, power is sent to the LH rear window control switch through circuit 2014 (YE/LB), which transfers power to the LH rear window motor through circuit 885 (YE/LB). Ground is provided to the LH rear window switch through circuit 2015 (GY/BK), which transfers ground to the LH rear window motor through circuit 884 (YE/BK).

When the RH rear power window is operated in the up direction from the LH front window control switch, power is sent to the RH rear window control switch through circuit 2013 (YE/BK), which transfers power to the RH rear window motor through circuit 882 (BN/YE). Ground is sent to the RH rear window switch through circuit 2012 (RD/BK), which transfers ground to the RH rear window motor through circuit 881 (BN).

During RH rear power window down operation from the LH front window control switch, power is sent to the RH rear window control switch through circuit 2012 (RD/BK), which transfers power to the RH rear window motor through circuit 881 (BN). Ground is sent to the RH rear window switch through circuit 2013 (YE/BK), which transfers ground to the RH rear window motor through circuit 882 (BN/YE).

1. Circuit 170 (RD/LB) open
2. Circuit 2013 (YE/BK) open (RH rear window)
3. Circuit 2012 (RD/BK) open (RH rear window)
4. Circuit 882 (BN/YE) open (RH rear window)
5. Circuit 881 (BN) open (RH rear window)
6. Circuit 2015 (GY/BK) open (LH rear window)
7. Circuit 2014 (YE/LB) open (LH rear window)
8. Circuit 884 (YE/BK) open (LH rear window)
9. Circuit 881 (BN) open (LH rear window)
10. LH front window switch
11. Rear window motor
12. Rear window switch

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Scheme 41

1. D1 CHECK THE VOLTAGE TO THE LH REAR OR RH REAR WINDOW CONTROL SWITCH Disconnect: Inoperative Rear Window Control Switch C701 or C801. Key in ON position. NOTE: Set the window lock switch to the unlock position. Measure the voltage between the inoperative rear window connector and ground: For the RH rear window control switch, measure the voltage between RH rear window control switch C801-5, circuit 170 (RD/LB), harness side and ground. For the LH rear window control switch, measure the voltage between C701-5, circuit 170 (RD/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to D2. No : REPAIR the circuit. TEST the system for normal operation.
2. D2 CHECK THE GROUNDS TO THE INOPERATIVE REAR WINDOW CONTROL SWITCH Key in OFF position. Measure the resistance between the inoperative window control switch and ground: For the RH rear window control switch, measure the resistance between RH rear window control switch C801-1, circuit 2013 (YE/BK), harness side and ground; and between RH rear window control switch C801-6, circuit 2012 (RD/BK), harness side and ground. For the LH rear window control switch, measure the resistance between LH rear window control switch C701-1, circuit 2015 (GY/BK), harness side and ground; and between LH rear window control switch C701-6, circuit 2014 (YE/LB), harness side and ground. Are the resistances less than 5 ohms? Yes : GO to D4 . No : GO to D3.
3. D3 CHECK THE CIRCUITS TO THE INOPERATIVE REAR WINDOW CONTROL SWITCH FOR AN OPEN Key in OFF position. Disconnect: LH Front Window Control Switch C504a. For an inoperative LH rear power window, measure the resistance between LH front window control switch C504a-2, circuit 2014 (YE/LB) and LH rear window control switch C701-6, circuit 2014 (YE/LB), harness side; and between LH front window control switch C504a-6, circuit 2015 (GY/BK) and LH rear window control switch C701-1, circuit 2015 (GY/BK) harness side. For an inoperative RH rear power window, measure the resistance between LH front window control switch C504a-3, circuit 2012 (RD/BK) and RH window control switch C701-6, circuit 2012 (RD/BK), harness side; and between front window control switch C504a-6, circuit 2013 (YE/BK) and RH rear window control switch C801-1, circuit 2013 (YE/BK) harness side. Are the resistances less than 5 ohms? Yes : INSTALL a new LH front window control switch. REFER to «WINDOW CONTROL SWITCH»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation. No : REPAIR the circuit(s) for an open. TEST the system for normal operation.
4. D4 CHECK THE INOPERATIVE WINDOW CONTROL SWITCH Connect: LH Front Window Control Switch C504a. Key in ON position. For an inoperative LH rear window, connect a fused jumper wire between LH rear window control switch C701-1, circuit 2015 (GY/BK), harness side and LH rear window control switch C701-4, circuit 882 (BN/YE), harness side; and between LH rear window control switch C701-3, circuit 885 (YE/LB), harness side and LH rear window control switch C701-5, circuit 170 (RD/LB), harness side. The LH rear window should operate in the downward direction. For an inoperative RH rear window, connect a fused jumper wire between RH rear window control switch C801-1, circuit 2013 (YE/BK), harness side and RH rear window control switch C801-4, circuit 884 (YE/BK), harness side; and between RH rear window control switch C801-5, circuit 881 (BN), harness side and RH rear window control switch C801-5, circuit 170 (RD/LB), harness side. The RH rear window should operate in the downward direction. For an inoperative LH rear window, connect a fused jumper wire between inoperative LH rear window control switch C701-3, circuit 885 (YE/LB), harness side and LH rear window control switch C701-6, circuit 2014 (YE/LB), harness side; and between LH rear window control switch C701-4, circuit 884 (YE/BK), harness side and LH rear window control switch C701-5, circuit 170 (RD/LB), harness side. The LH rear window should operate in the upward direction. For an inoperative RH rear window, connect a fused jumper wire between RH rear window control switch C801-3, circuit 881 (BN), harness side and RH rear window control switch C801-6, circuit 2012 (RD/BK), harness side; and between RH rear window control switch C801-4, circuit 882 (BN/YE), harness side and RH rear window control switch C801-5, circuit 170 (RD/LB), harness side. The RH rear window should operate in the upward direction. Did the inoperative window operate correctly? Yes : INSTALL a new LH or RH rear window control switch. REFER to «WINDOW CONTROL SWITCH»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation. No : GO to D5.
5. D5 CHECK THE POWER WINDOW MOTOR CIRCUITS Key in OFF position. Disconnect: Inoperative Rear Window Motor C703 (LH) or C803 (RH). For an inoperative LH rear window, measure the resistance between LH rear window control switch C701-3, circuit 885 (YE/LB), harness side and LH rear window motor C703-1, circuit 885 (YE/LB), harness side. For an inoperative RH rear window, measure the resistance between RH rear window control switch C801-3, circuit 881 (BN), harness side and RH rear window motor C803-1, circuit 881 (BN), harness side. For an inoperative LH rear window, measure the resistance between LH rear window control switch C701-4, circuit 884 (YE/BK), harness side and LH rear window motor C703-1, circuit 884 (YE/BK), harness side. For an inoperative RH rear window, measure the resistance between RH rear window control switch C801-4, circuit 882 (BN/YE), harness side and RH rear window motor C703-2, circuit 882 (BN/YE), harness side. Are the resistances less than 5 ohms? Yes : INSTALL a new LH or RH rear window motor. REFER to «WINDOW REGULATOR MOTOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.

Pinpoint Test E: The One-Touch Up/Down Feature Is Inoperative - LH Front Window Only

Note. A new LH front power window motor will only operate in proportional up or down mode until initialized. Refer to DOOR WINDOW MOTOR INITIALIZATION .

Note. The LH front power window motor must be initialized whenever a new motor is installed.

Note. The LH front power window motor must be de-initialized, then initialized whenever the LH front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new window glass is installed, a new top run is installed, or for any operation in which grease or lubricants are applied to the window regulator or glass run.

The LH front power window control switch receives power from the delayed accessory relay through circuit 1499 (PK/LG) and is grounded through circuit 1205 (BK). When the LH front window control switch is pressed to the up position, the LH front motor receives power through circuit 226 (WH/BK). When the LH front window control switch is pressed to the down position, the LH front motor receives power through circuit 227 (YE). When the LF window motor receives a ground signal on circuit 2018 (OG/YE) the LF window motor will enter one-touch down.

1. B(+) power lost during LH front window operation
2. Inoperative LH front window motor
3. Inoperative LH front window control switch
4. LH front motor not initialized
5. Open in circuit 2018 (OG/YE)

Scheme 42

Scheme 43

1. E1 CHECK FOR POWER (B+) LOSS DURING LH FRONT WINDOW OPERATION Verify if power (B+) was lost during LH front window operation. Was power (B+) lost while LH front window was in operation? Yes : RAISE the LH front window to the fully closed position. VERIFY the window glass stalls into the upper header seal. The LH front window should function normally. TEST the system for normal operation. No : GO to E2.
2. E2 DE-INITIALIZE, THEN INITIALIZE THE LH FRONT MOTOR De-initialize the LH front window motor, then carry out the LH front window motor initialization procedure. Refer to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . Is the one-touch down feature operating correctly? Yes : The system is operating normally at this time. The LH front window motor lost initialization. No : GO to E3.
3. E3 CHECK THE LH FRONT WINDOW CONTROL SWITCH Key in OFF position. Disconnect: LH Front Window Control Switch. Carry out the LH front window switch component test. Refer to «COMPONENT TESTING»(/ford/five-hundred/i-2004-2007/remont/accessories-control-systems/#component-testing) . Did the LH front window switch pass the component test? Yes : GO to E4. No : INSTALL a new LH front window control switch. REFER to «WINDOW CONTROL SWITCH»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation.
4. E4 CHECK CIRCUIT 2018 (OG/YE) FOR AN OPEN Disconnect: LH Front Window Control Switch C504b. Disconnect: LH Front Window Motor C524. Measure the resistance between LH front window control switch C504b-3, circuit 2018 (OG/YE), harness side and LH front window motor connector C524-2, circuit 2018 (OG/YE). Is the resistance less than 5 ohms? Yes : GO to E5. No : REPAIR the circuit. DE-INITIALIZE, then INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation.
5. E5 CHECK FOR INTERMITTENT GROUND CONNECTIONS Measure the resistance between LH front window motor C524-4, circuit 1205 (BK), harness side and ground. Wiggle the harness while measuring the resistance. Is the resistance less than 5 ohms? Yes : GO to E6. No : REPAIR the circuit. DE-INITIALIZE, then INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation.
6. E6 CHECK FOR INTERMITTENT POWER CONNECTIONS Key in ON position. Measure the voltage between LH front window motor C524-1, circuit 995 (GY), harness side and ground; and between LH front window motor C524-3, circuit 2086 (RD/LB), harness side and ground. Are the voltages greater than 10 volts? Yes : INSTALL a new LH front power window motor. REFER to «WINDOW REGULATOR MOTOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . INITIALIZE the LH front window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation. No : REPAIR the circuit. DE-INITIALIZE, then INITIALIZE the LH front power window motor. REFER to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . TEST the system for normal operation.

The heated backlight relay, which is integral to the smart junction box (SJB), receives power from circuit 1846 (GY/LB). When the rear window defrost switch is pressed on the electronic automatic temperature control (EATC) or electronic manual temperature control module (EMTC) control unit, a message is sent to the SJB through circuit 1426 (PK). Once the SJB receives the message to turn on the rear window defrost, the SJB grounds the heated backlight relay coil, which sends power to the rear window defrost grid through circuit 186 (BN/LB) from the SJB. The rear window defrost grid uses circuit 1205 (BK) for ground.

1. Inoperative SJB
2. Inoperative EATC or EMTC
3. Open in circuits 1846 (GY/LB), 1426 (PK), 1205 (BK), or 186 (BN/LB)

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. F1 CHECK THE REAR DEFROST INDICATOR LAMP Key in ON position. Turn the rear defroster ON. Does the rear defrost indicator lamp illuminate? Yes : GO to F3 . No : GO to F2.
2. F2 CHECK FOR POWER TO THE SJB HEATED BACKLIGHT CIRCUIT Disconnect: SJB C2280a. Key in ON position. Measure the voltage between SJB C2280a-4, circuit 1846 (GY/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to F3. No : REPAIR the circuit. TEST the system for normal operation.
3. F3 CHECK THE SJB OUTPUT Key in OFF position. Connect: SJB C2280a. Disconnect: Heated Backlight Power C396. Key in ON position. Turn the rear defroster ON. Measure the voltage between rear window defrost grid power C402a, circuit 186 (BN/LB) and ground. Is the voltage greater than 10 volts? Yes : GO to F4. No : GO to F5 .
4. F4 CHECK THE REAR WINDOW DEFROST GRID GROUND Key in OFF position. Disconnect: Heated Backlight Ground C397. Measure the resistance between rear window defrost grid ground C402b, circuit 1205 (BK) and ground. Is the resistance less than 5 ohms? Yes : GO to F5. No : REPAIR the rear window defrost grid or INSTALL a new rear window or liftgate window glass. REFER to «WINDOW GRID WIRE REPAIR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) , «WINDOW GLASS - REAR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) , «WINDOW GLASS - LIFTGATE»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) . TEST the system for normal operation.
5. F5 CHECK CIRCUIT 186 (BN/LB) FOR AN OPEN Key in ON position. Measure the resistance between heated backlight grid C396-1, circuit 186 (BN/LB), harness side and SJB C2280e-32, circuit 186 (BN/LB), harness side. Is the resistance less than 5 ohms? Yes : GO to F6. No : REPAIR the circuit. TEST the system for normal operation.
6. F6 CHECK THE SJB HEATED BACKLIGHT RELAY PID Monitor the SJB heated backlight PID while triggering the SJB active command heated backlight relay. Does the SJB heated backlight relay PID value agree with the command mode? Yes : GO to F7. No : INSTALL a new SJB. TEST the system for normal operation
7. F7 CHECK CIRCUIT 1426 (PK) AND 1427 (TN/LB) FOR AN OPEN Key in OFF position. Disconnect: EATC C228a or EMTC C294a. Disconnect: SJB C2280b and C2280d. For manual climate control, measure the resistance between SJB C2280d-27, circuit 1426 (PK), harness side and EMTC module C294a-10, circuit 1426 (PK), harness side; and between SJB C2280b-25, circuit 1427 (TN/LB), harness side, and EMTC module C294a-4, circuit 1427 (TN/LB), harness side. For automatic climate control, measure the resistance between SJB C2280d-27, circuit 1426 (PK), harness side and EATC module C228a-10, circuit 1426 (PK), harness side; and between SJB C2280b-25, circuit 1427 (TN/LB), harness side, and EATC module C228a-4, circuit 1427 (TN/LB), harness side. Are all resistances less than 5 ohms? Yes : INSTALL a new EATC or EMTC module. REFER to «AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/automatic-hvac-system/#hvac-system-air-distribution-system-filtering-system) . TEST the system for normal operation. No : REPAIR the circuit(s). TEST the system for normal operation

The heated backlight relay, which is integral to the SJB, receives power from circuit 1846 (GY/LB). When the rear window defrost switch is pressed on the electronic automatic temperature control (EATC) or electronic manual temperature control (EMTC) module, a message is sent to the smart junction box (SJB) through circuit 1426 (PK). Once the SJB receives the message to turn on the rear window defrost, the SJB activates the heated backlight relay. Power is then sent to the rear window defrost grid through circuit 186 (BN/LB) from the SJB heated backlight relay circuit. The rear window defrost grid then receives ground through circuit 1205 (BK) to chassis ground.

1. Inoperative SJB
2. Circuit 186 (BN/LB) shorted to power
3. Circuit 1427 (TN/LB) shorted to power

Scheme 49

1. G1 CHECK CIRCUIT 186 (BN/LB) FOR A SHORT TO VOLTAGE Disconnect: SJB C2280e. Key in ON position. Is the rear window defrost ON? Yes : REPAIR circuit 186 (BN/LB) for a short to voltage. TEST the system for normal operation. No : GO to G2.
2. G2 CHECK THE SJB HEATED BACKLIGHT RELAY CIRCUIT FOR A SHORT TO POWER Key in OFF position. Connect: SJB C2280e. Disconnect: Heated Backlight Grid C396. Key in ON position. Measure the voltage between heated backlight connector C396-1, circuit 186 (BN/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to G3. No : GO to G4 .
3. G3 CHECK CIRCUIT 1427 (TN/LB) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: SJB C2280b. Measure the voltage between SJB C2280b-25, circuit 1427 (TN/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : REPAIR the circuit. TEST the system for normal operation. No : GO to G4.
4. G4 CHECK FOR CORRECT SJB OPERATION Disconnect all SJB connectors. Check for: corrosion pushed-out pins Connect all SJB connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new SJB. REFER to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#multifunction-electronic-modules-system) for the removal and installation procedure. TEST the system for normal operation. No : The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

The delayed accessory relay, which is integral to the smart junction box (SJB), receives power from the central junction box (CJB) through circuit 905 (GY/LB). When the ignition key is turned ON, the SJB activates the delayed accessory relay, which provides power to the LH front window control switch through circuit 1499 (PK/LG). The delayed accessory feature remains active for 10 minutes after the ignition key is turned OFF, or until either front door is opened.

1. Circuit 905 (GY/LB) or 1499 (PK/LG) open
2. Inoperative SJB.
3. Inoperative door ajar switches.

Scheme 50

1. H1 CHECK FOR CORRECT OPERATION OF THE INTERIOR LIGHTS Open and close the front doors. Verify the interior lights turn ON when the doors are open, and OFF when the doors are closed. Do the interior lights operate normally? Yes : GO to H2. No : REFER to «INTERIOR LIGHTING»(/ford/five-hundred/i-2004-2007/remont/interiorillumination-lights/#interior-lighting-system) to diagnose the interior lighting and door ajar switches.
2. H2 CHECK CIRCUIT 905 (GY/LB) FOR VOLTAGE Disconnect: SJB C2280g. Key in ON position. Measure the voltage between SJB C2280g-2, circuit 905 (GY/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to H3. No : REPAIR the circuit. TEST the system for normal operation.
3. H3 CHECK CIRCUIT 1499 (PK/LG) FOR AN OPEN Disconnect: LH Front Window Control Switch C504a. Measure the resistance between LH front window control switch C504a-5, circuit 1499 (PK/LG), harness side and SJB C2280e-4, circuit 1499 (PK/LG), harness side. Is the resistance less than 5 ohms? Yes : GO to H4. No : REPAIR the circuit. TEST the system for normal operation.
4. H4 CHECK FOR CORRECT SJB OPERATION Disconnect all SJB connectors. Check for: corrosion pushed-out pins Connect all SJB connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new SJB. REFER to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#multifunction-electronic-modules-system) for the removal and installation procedure. TEST the system for normal operation. No : The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

Material

MATERIAL SPECIFICATIONS

Repair

Note. If the first layer of the heated rear window grid (brown) is damaged or missing, it is necessary to apply touch up paint on the glass prior to applying the silver rear window defroster repair.

Note. The grid line material is not embedded into the glass but is baked to the glass surface and consequently can be scraped off. Inoperative lines may appear to the eye to be undamaged due to residue remaining on the glass and will require diagnosis with a voltmeter or 12V test lamp. For additional information, refer to DIAGNOSIS AND TESTING .

Note. An undamaged grid line will have small ridges that project above the surface of the glass and can easily be felt when running a fingernail across them. Grid lines that have been "razor bladed" will feel smooth when a fingernail is dragged across the affected area. There may be some residue left on the glass that appears to be grid material but a check with a voltmeter or 12V test lamp will confirm an open circuit.

Note. If the brown color under the grid line is damaged or missing (this is very rare), it will be necessary to apply lacquer touch-up paint for color match. This paint must meet specification and should be applied to the glass prior to applying the rear window defroster repair compound.

Note. The interior side of the grid lines are not painted, but due to the silver tarnishing will tend to change the grid to a gold or brown color. The repair area will be bright silver and will also tarnish over time to match the rest of the grid.

Scheme 51

Scheme 52

1. Bring the vehicle up to room temperature of at least 16°C (60°F) or above.
2. Clean the entire grid line repair area with window cleaner and 0000 steel wool to remove all dirt, wax, grease, oil or other foreign material.
3. Mark the location of the grid break on the exterior of the rear window glass.
4. Using a polypropylene film fine line tape, mask the area directly above and below the grid break extending the tape 26 mm (1.02 in) beyond the concern area in both directions. The break area should be at the center of the mask.
5. Apply the repair coating to the grid break area in several smooth, continuous strokes. Apply a minimum of 6 applications of the grid repair compound.
6. After 5 minutes, or after the repair area has dried completely, remove the mask.
7. Remove any excess repair compound above or below the grid line with a razor blade.
8. Test the system for normal operation.

MATERIAL SPECIFICATIONS

1. Clean the bus bar in the area to be repaired with steel wool (3.0 to 4.0 grade), and then with window cleaner to remove all dirt, wax, grease, oil or other foreign material.
2. Place the replacement terminal type A over the original tab location, making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material.
3. Hold the terminal in place with an item such as a regular lead pencil at a 90 degree angle from the terminal. (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies.)
4. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25--45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional 30 seconds.
5. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another 2 minutes before the wiring lead is attached to the terminal.
6. Attach the electrical lead connection to this terminal, turn on the heated rear window and verify the operation.

Door Window Motor Initialization

Note. A new (original factory setting) or de-initialized LH front window motor will only operate in proportional up/down and one-touch-down mode until initialized. If a new LH front window motor has been installed, proceed to the initialization procedure.

Note. If diagnosing a LH front window switch problem, perform the window initialization procedure before replacing the window switch.

Note. The LH front window motor will not function in one-touch-up mode if it is not initialized.

Note. All LH front window components (window glass, window regulator, window motor, seals and glass top run) must be installed and tightened to specification before carrying out the initialization procedure.

Note. If the initialization procedure is only partially completed, the LH front window motor will remain un-initialized and will operate only in proportional up/down and one-touch-down modes.

Note. The front window motors must be initialized whenever: a new window regulator and motor is installed, a new window glass is installed, a glass top run removal and installation or when carrying out any operation in which grease or lubricants are applied to the window system. A new front window motor is only in a proportional up/down and one-touch-down mode until initialized.

De-initialization procedure

MATERIAL SPECIFICATIONS

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Remove the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(/ford/five-hundred/i-2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
2. Position the LH and RH weatherstrips aside.
3. Remove the LH and RH A-pillar trim panels.
4. Remove the LH and RH sun visors. Remove the 4 screws. Disconnect the electrical connectors. Remove the visors and the clips.
5. If equipped, remove the overhead console.
6. Open the assist handle screw covers.
7. Remove the 2 assist handle screws and the assist handle.
8. Lower the front portion of the headliner and block with a suitable material.
9. Clean the interior and exterior of the windshield glass surface with glass cleaner.
10. Cut the urethane adhesive applicator tip to 6 mm (0.23 in).
11. Apply urethane adhesive over top of the existing urethane adhesive. Apply the urethane to the top and sides of the windshield from the interior of the vehicle. Apply the urethane to the bottom of the windshield from the exterior of the vehicle.
12. After the urethane has cured, check the windshield seal for air or water leaks through the urethane bead and add urethane adhesive as necessary.
13. Position the front portion of the headliner.
14. Position the LH and RH assist handles and install the 2 screws.
15. Close the assist handle screw covers.
16. If equipped, install the overhead console.
17. Install the LH and RH sun visors. Install the clips. Connect the electrical connectors and install the visors. Install the 4 screws.
18. Install the LH and RH A-pillar trim panels.
19. Install the LH and RH weatherstrips.
20. Install the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(/ford/five-hundred/i-2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
21. Clean the interior and exterior windshield glass with glass cleaner.

Scheme 60

1. For additional information, refer to the procedures below.

Removal and Installation

Note. If installing a new LH front window motor, it must be initialized.

Note. The LH front window motor must be de-initialized, then initialized whenever the LH front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new window glass is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run.

Scheme 61

Scheme 62

1. Remove the front door trim panel and water shield. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Remove the front door speaker. For additional information, refer to «SPEAKERS»(/ford/five-hundred/i-2004-2007/remont/entertainment-systems/#speaker-system) .
3. Lower the window until the glass clamp bolts can be accessed through the rear access hole and front door speaker opening.
4. Loosen the B-pillar front door window glass clamp bolt. To install, tighten to 8 Nm (71 lb-in).
5. Loosen the A-pillar front door window glass clamp bolt. To install, tighten to 8 Nm (71 lb-in).
6. Tape the window in position, then lower the window regulator downward until it reaches the stops at the bottom of the regulator tracks.
7. Lift the window glass out of the door.
8. To install, reverse the removal procedure. If installing a new LH front window motor, it must be initialized. For additional information, refer to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . If installing the original LH front window motor, it must be de-initialized, then initialized. For additional information, refer to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) .

Note. If installing a new LH front window motor, it must be initialized.

Note. The LH front window motor must be de-initialized, then initialized whenever the LH front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new window glass is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run.

1. Remove the door trim panel and water shield. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Disconnect the window motor electrical connector.
3. Secure the glass in position with tape.
4. Remove the 3 window motor screws.
5. Remove the window motor.
6. To install, reverse the removal procedure. If installing a new LH front window motor, it must be initialized. For additional information, refer to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . If installing the original LH front window motor, it must be de-initialized, then initialized. For additional information, refer to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) .

Note. If installing a new LH front window motor, it must be initialized.

Note. The LH front window motor must be de-initialized, then initialized whenever the LH front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new window glass is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run.

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Remove the door trim panel and water shield. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Remove the front door speaker. For additional information, refer to «SPEAKERS»(/ford/five-hundred/i-2004-2007/remont/entertainment-systems/#speaker-system) .
3. Remove the access hole cover, then disconnect the 2 door latch electrical connectors.
4. If equipped, disconnect the keyless entry keypad and door lock electrical connectors.
5. If equipped, disconnect the power mirror electrical connector.
6. Disconnect the door latch and door lock linkages. Disconnect the clips.
7. Disconnect the window motor electrical connector, then position the wiring harness aside. Disconnect the 4 wiring harness retainers and the grommet. Push the grommet through the opening and into the door panel.
8. Remove the interior door handle bolt, and position the door handle aside. To install, tighten to 7 Nm (62 lb-in).
9. Lower the window until the glass clamp bolts can be accessed through the rear access hole and front door speaker opening.
10. Loosen the B-pillar front door window glass clamp bolt. To install, tighten to 8 Nm (71 lb-in).
11. Loosen the A-pillar front door window glass clamp bolt. To install, tighten to 8 Nm (71 lb-in).
12. Tape the window in position, then lower the window regulator downward until it reaches the stops at the bottom of the regulator tracks.
13. Remove the 11 bolts from the door module. To install, tighten to 8 Nm (71 lb-in).
14. Remove the 3 door latch screws. To install, tighten to 12 Nm (9 lb-ft).
15. Disconnect the 6 wiring harness retainers and the 2 connector retainers from the inside of the door module, then feed the wiring harness through the door module.
16. Remove the front door module. If installing a new door module, transfer parts as necessary.
17. To install, reverse the removal procedure. If installing a new LH front window motor, it must be initialized. For additional information, refer to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) . If installing the original LH front window motor, it must be de-initialized, then initialized. For additional information, refer to «DOOR WINDOW MOTOR INITIALIZATION»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass__door-window-motor-initialization) .

Scheme 70

Scheme 71

Scheme 72

1. Remove the front door window glass. For additional information, refer to «WINDOW GLASS - FRONT DOOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) .
2. Remove the front door window glass inner weatherstrip.
3. Remove the door glass track bolt. To install, tighten to 8 Nm (71 lb-in).
4. Remove the front door glass top run.
5. To install, reverse the removal procedure.

Glass, Frames and Mechanisms - Exploded View, Rear Door

Note. Ford Five Hundred and Montego shown, Freestyle similar.

Scheme 73

1. For additional information, refer to the procedures in this article.

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

1. Remove the rear door trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Remove the access hole plug.
3. Lower the window until the glass clamp bolt is accessible through the access hole plug, then loosen the glass clamp bolt. To install, tighten to 9 Nm (80 lb-in).
4. Tape the window in position, then lower the window regulator downward until it reaches the stops at the bottom of the regulator tracks.
5. Lower the window glass into the door.
6. Remove the top run.
7. Remove the rear fixed window glass. Remove the bolt and the screw.
8. Lower the window glass into the door.
9. Remove the scrivet from the rear door glass top run.
10. Remove the bolt from the rear door glass top run.
11. Remove the top run and bracket.
12. Remove the rear window glass.
13. To install, reverse the removal procedure.

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

1. Remove the rear door trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Remove the door speaker. For additional information, refer to «SPEAKERS»(/ford/five-hundred/i-2004-2007/remont/entertainment-systems/#speaker-system) .
3. Rotate the lock rod downward to align the shaft with the slot in the door lock linkage.
4. Slide the lock rod out of the door lock linkage.
5. Disconnect the door lock and rear window motor electrical connectors.
6. Remove the 3 door latch screws.
7. Remove the access hole cover.
8. Lower the window until the glass clamp bolt is accessible through the access hole plug, then loosen the glass clamp bolt. To install, tighten to 9 Nm (80 lb-in).
9. Tape the window glass in position.
10. Disconnect the 5 wiring harness retainers and the wiring harness grommet.
11. Remove the interior door handle bolt. To install, tighten to 7 Nm (62 lb-in).
12. Remove the 8 bolts from the door module. To install, tighten to 8 Nm (71 lb-in).
13. Feed the wiring harness and grommet, and the interior door handle and cable through the openings in the rear door module, then remove the door module.
14. To install, reverse the removal procedure.

1. Remove the rear door trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Remove the rear door module. For additional information, refer to «WINDOW REGULATOR MOTOR - REAR DOOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) .
3. Lower the rear door window glass into the door.
4. Remove the scrivet.
5. Remove the rear door glass top run bolt.
6. Remove the rear door glass inner weatherstrip.
7. Carefully position the glass aside, then remove the rear door glass top run.
8. To install, reverse the removal procedure.

Scheme 87

1. Remove the window regulator control switch bezel. Remove the 2 screws. Disconnect the electrical connectors.
2. Remove the window control switch.
3. To install, reverse the removal procedure.

SPECIAL TOOL DESCRIPTION Interior Auto Glass Cut-Out Knife Kit (Electric) 164-R2450 or equivalent Pneumatic Knife with Offset Blade 107-R1511 or equivalent The Pumper 164-R2459 or equivalent

Scheme 88

Scheme 89

MATERIAL SPECIFICATIONS

Scheme 90

Scheme 91

Scheme 92

1. Remove the C-pillar trim panel and parcel shelf, and lower the headliner. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Disconnect the 2 rear window defrost electrical connectors.
3. Using the special tool, place the flat side of the knife against the rear window glass window. Start cutting the glass at the top and work toward the corners.
4. Using the special tool, distance the rear window glass from the body.
5. Using the special tool, cut the remaining urethane adhesive and remove the window glass.
6. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

Installation

Note. For additional material guidelines, refer to the manufacturer's installation information.

Scheme 93

1. Dry fit the rear window glass to the existing urethane adhesive bead on the body pinch weld. Align the rear window glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks on the rear window glass at the setting blocks and the body to aid in the installation alignment of the rear window glass.
3. Remove the rear window glass.
4. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm base of original equipment urethane on the pinchweld.
5. If installing the original rear window glass, remove the excess urethane adhesive.
6. Clean the inside of the rear window glass surface with glass cleaner.
7. If installing a new rear window glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
8. Cut the urethane adhesive applicator tip to specification.
9. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the rear window glass near the center.
10. Install the rear window glass on the vehicle aligning it with the markings made previously.
11. After the urethane has cured, check the rear window glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
12. Install the headliner, parcel shelf and C-pillar trim panels. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
13. Connect the LH and RH heated rear window electrical connector.

SPECIAL TOOL DESCRIPTION Interior Auto Glass Cut-Out Knife Kit (Electric) 164-R2450 or equivalent Pneumatic Knife with Offset Blade 107-R1511 or equivalent

MATERIAL SPECIFICATIONS

Scheme 94

1. Remove the parcel shelf, C-pillar and D-pillar trim panels. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Using the special tool, place the flat side of the knife against the rear quarter glass window. Start cutting the glass at the middle of the D-pillar, and work toward the roof.
3. Remove the rear quarter window glass.
4. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

Note. For additional material guidelines, refer to the manufacturer's installation information.

1. Dry fit the rear quarter window glass to the existing urethane adhesive bead on the body pinch weld. Align the rear quarter window glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks on the rear quarter window glass at the setting blocks and the body to aid in the installation alignment of the rear quarter window glass.
3. Remove the rear quarter window glass.
4. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm base of original equipment urethane on the pinchweld.
5. If installing the original rear quarter window glass, remove the excess urethane adhesive.
6. Clean the inside of the rear quarter window glass surface with an alcohol-free glass cleaner.
7. If installing a new rear quarter window glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
8. Cut the urethane adhesive applicator tip to specification.
9. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the rear quarter window glass opening near the center.
10. Install the rear quarter window glass on the vehicle aligning it with the markings made previously.
11. After the urethane has cured, check the rear quarter window glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
12. Install the parcel shelf, C-pillar and D-pillar trim panels. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .

Scheme 95

1. Remove the rear door trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Remove the rear door window glass. For additional information, refer to «WINDOW GLASS - REAR DOOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) .
3. Remove the rear door module. For additional information, refer to «WINDOW REGULATOR MOTOR - REAR DOOR»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) .
4. Remove the rear door glass interior weatherstrip.
5. Remove the rear door window glass top run screw.
6. Remove the rear door window glass top run.
7. Remove the rear door fixed window glass bolt. To install, tighten to 7 Nm (62 lb-in).
8. Remove the rear door fixed window glass.
9. To install, reverse the removal procedure.

SPECIAL TOOL DESCRIPTION Interior Auto Glass Cut-Out Knife Kit (Electric) 164-R2450 or equivalent Pneumatic Knife with Offset Blade 107-R1511 or equivalent

MATERIAL SPECIFICATIONS

Scheme 96

Scheme 97

1. Remove the rear window wiper arm and motor. For additional information, refer to «WIPERS AND WASHERS»(/ford/five-hundred/i-2004-2007/remont/wiperwasher-systems/#wiper-system-washer-system) .
2. Remove the liftgate trim panel. For additional information, refer to «WIPERS AND WASHERS»(/ford/five-hundred/i-2004-2007/remont/wiperwasher-systems/#wiper-system-washer-system) .
3. Disconnect the 2 rear window defrost electrical connectors.
4. Using the special tool, cut the adhesive away from the liftgate window glass and remove the liftgate window glass.
5. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

Note. For additional material guidelines, refer to the manufacturer's installation information.

1. Dry fit the liftgate window glass to the existing urethane adhesive bead on the body pinch weld. Align the liftgate window glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks on the liftgate window glass at the setting blocks and the body to aid in the installation alignment of the liftgate window glass.
3. Remove the liftgate window glass.
4. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm base of original equipment urethane on the pinchweld.
5. If installing the original liftgate window glass, remove the excess urethane adhesive.
6. Clean the inside of the liftgate window glass surface with glass cleaner.
7. If installing a new liftgate window glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
8. Cut the urethane adhesive applicator tip to specification.
9. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the liftgate window glass opening near the center.
10. Install the liftgate window glass on the vehicle aligning it with the markings made previously.
11. After the urethane has cured, check the liftgate window glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
12. Install the liftgate trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .

SPECIAL TOOL DESCRIPTION Interior Auto Glass Cut-Out Knife Kit (Electric) 164-R2450 or equivalent Pneumatic Knife with Offset Blade 107-R1511 or equivalent

MATERIAL SPECIFICATIONS

Scheme 98

1. Remove the C-pillar, D-pillar and rear quarter trim panels. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. From the outside of the vehicle, using the special tool, cut the top portion of glass.
3. From inside the vehicle, using the special tool, cut the glass starting at the upper C-pillar and work down, across the bottom, then upward toward the upper D-pillar.
4. Remove the rear quarter window glass.
5. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

Note. For additional material guidelines, refer to the manufacturer's installation information.

1. Dry fit the rear quarter window glass to the existing urethane adhesive bead on the body pinch weld. Align the rear quarter window glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks on the rear quarter window glass at the setting blocks and the body to aid in the installation alignment of the rear quarter window glass.
3. Remove the rear quarter window glass.
4. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm base of original equipment urethane on the pinchweld.
5. If installing the original rear quarter window glass, remove the excess urethane adhesive.
6. Clean the inside of the rear quarter window glass surface with glass cleaner.
7. If installing a new rear quarter window glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
8. Cut the urethane adhesive applicator tip to specification.
9. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the rear quarter window glass opening near the center.
10. Install the rear quarter window glass on the vehicle aligning it with the markings made previously.
11. After the urethane has cured, check the rear quarter window glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
12. Install the C-pillar, D-pillar and rear quarter trim panels. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .

SPECIAL TOOL DESCRIPTION Interior Auto Glass Cut-Out Knife Kit (Electric) 164-R2450 or equivalent Pneumatic Knife with Offset Blade 107-R1511 or equivalent The Pumper 164-R2459 or equivalent

MATERIAL SPECIFICATIONS

Removal

Note. Five Hundred shown, all others similar.

Scheme 99

Scheme 100

1. Remove the A-pillar trim panels. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Remove the interior mirror. For additional information, refer to «REAR VIEW MIRRORS»(/ford/five-hundred/i-2004-2007/remont/mirrors/#rear-view-mirror-system) .
3. Partially lower the front portion of the headliner near the windshield header and block with suitable material. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
4. Remove the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(/ford/five-hundred/i-2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
5. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and working toward the bottom corners.
6. Using the special tool, distance the windshield glass from the body.
7. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
8. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

Note. For additional material guidelines, refer to the manufacturer's installation information.

1. Dry fit the windshield glass to the existing urethane adhesive bead on the body pinch weld. Align the windshield glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks on the windshield glass at the setting blocks and the body to aid in the installation alignment of the windshield glass.
3. Remove the windshield glass.
4. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm base of original equipment urethane on the pinchweld.
5. If installing the original windshield glass, remove the excess urethane adhesive.
6. Clean the inside of the windshield glass surface with glass cleaner.
7. If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
8. Cut the urethane adhesive applicator tip to specification.
9. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the windshield near the center.
10. Install the windshield glass on the vehicle aligning it with the markings made previously.
11. After the urethane has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
12. Install the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(/ford/five-hundred/i-2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
13. Install the headliner. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
14. Install the interior mirror. For additional information, refer to «REAR VIEW MIRRORS»(/ford/five-hundred/i-2004-2007/remont/mirrors/#rear-view-mirror-system) .
15. Install the A-pillar trim panels. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .

See also:
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• COMPONENT TESTING
• AIR DISTRIBUTION & FILTERING
• INTERIOR LIGHTING
• FRONT END BODY PANELS
• INTERIOR TRIM AND ORNAMENTATION
• SPEAKERS
• WIPERS AND WASHERS
• REAR VIEW MIRRORS
• DOOR WINDOW MOTOR INITIALIZATION
• SMART JUNCTION BOX (SJB) DIAGNOSTIC TROUBLE CODE (DTC) INDEX
• SYMPTOM CHART
• PINPOINT TEST F
• PINPOINT TEST B
• PINPOINT TEST E