Glass, Frames and Mechanisms: Removal & Installation Ford Thunderbird XI

Removal and Installation

Note. Driver door shown; passenger door similar.

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1. Position the door switch panel aside. Remove the door handle cup cover and the screw. Release the locking tabs at the front of the door switch panel.
2. Disconnect the electrical connector.
3. Release the retaining clips and remove the window control switch from the panel.
4. To install, reverse the removal procedure.

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1. If equipped, remove the removable top.
2. Remove the door trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-204609) .
3. Remove the water shield.
4. Connect the window switch.
5. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-204581) .
6. Fully lower the window.
7. Remove the pin-type retainer and the interior weatherstrip.
8. Remove the beltline moulding.
9. Position the door window glass to access the door window regulator clamp bolts.
10. Remove the two door window regulator clamp bolts and sleeve assemblies.
11. Remove the door window glass.

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Scheme 62

1. Position the door window glass into the window regulator clamps. Install the two bolt and sleeve assemblies into the window regulator clamps but do not tighten.
2. Remove the screw and the No. 4 convertible top weatherstrip.
3. Raise the door window glass to the full up position.
4. Install a 13 mm (0.52 in) wedge between the top of the glass and the convertible top No. 4 frame.
5. Tighten the two door window regulator clamp bolts.
6. Remove the 13 mm (0.52 in) wedge.
7. Fully lower the window.
8. Install the beltline moulding.
9. Install the interior weatherstrip and the pin-type retainer.
10. Install the No. 4 convertible top weatherstrip and the screw.
11. Operate the door window glass and check for binding and correct alignment.
12. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-204581) .
13. Disconnect the window switch.
14. Install the water shield.
15. Install the door trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-204609) .
16. If equipped, install the removable top.
17. Perform the door window motor initialization. For additional information, refer to «DOOR WINDOW MOTOR INITIALIZATION»(ref-204634-S19848727692005111300000) .

Scheme 63

Removal

Note. For the removal and installation of the convertible top rear window glass, refer to CONVERTIBLE TOP .

1. Remove the removable top from the vehicle.
2. Remove the package tray from the removable top.
3. Position the headliner aside.
4. Disconnect the two heated grid electrical connectors.
5. Using a soft brush or vacuum, remove dirt and foreign material from the adhesive area.
6. Using the special tool, starting at the top center of the rear window glass, cut the urethane adhesive away from the glass and work down the sides.
7. Remove the rear window glass.
8. Using a soft brush or vacuum, remove dirt and foreign material from the adhesive area.

Installation

Scheme 64

1. Dry fit the new rear window glass to the existing urethane bed on the adhesive area. Align the rear window glass in the opening for uniform fit.
2. Use tape or non-permanent marking pencil to make alignment marks on the rear window and the body to aid in the installation of the new rear window glass.
3. After alignment, remove the rear window glass from the vehicle and place on a stable work surface.
4. Trim the remaining urethane adhesive on the adhesive area. The urethane must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.
5. Use the wool applicator to apply Urethane Primer Essex meeting Ford specification WSB-M2G234-C to any exposed material on the urethaned area. Allow 6 to 10 minutes to dry.
6. If reinstalling the original rear window glass, trim the remaining urethane adhesive from the rear window glass surface, leaving a thin layer for adhering to the new urethane bead.
7. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
8. Align the "V" notch in the ceramic paint and rear window glass center. Fully seat the rear window glass outside molding along the top edge of the rear window glass and along the sides and bottom edges of the rear window glass.
9. If installing a new rear window glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M5B280-C twice around the glass surface to be prepped.
10. If installing a new rear window glass, apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M2G314-B to the same area that was prepped in the previous step. Allow five minutes to dry.
11. Cut the urethane adhesive applicator tip to specification.
12. Apply a bead of Urethane Adhesive Essex 400-HV meeting Ford specification WSB-M2G316-B to the urethaned area.
13. Install the rear window glass on the vehicle, aligning it with marks made previously.
14. Check the rear window installation for air or water leaks through the urethane bead.
15. Place two strips of tape onto the rear window glass and secure it to the removable top. This will help avoid misalignment while the urethane cures.
16. Connect the two heated grid electrical connectors.
17. Install the headliner.
18. Install the package tray.
19. Install the removable top on the vehicle.

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Scheme 66

1. Remove the door window glass. For additional information, refer to «DOOR WINDOW GLASS»(ref-204634-S29268288692005111300000) .
2. Remove the door window regulator and motor assembly. Disconnect the electrical connector. Remove the window regulator motor nuts. Remove the window regulator nuts.
3. Remove the screws and the motor from the front door window regulator.
4. To install, reverse the removal procedure.

Scheme 67

Note. The vehicle must remain inside until the windshield adhesive has cured.

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1. If installed, remove the removable top or lower the convertible top.
2. Remove the interior rear view mirror. For additional information, refer to «REAR VIEW MIRRORS»(ref-204625) .
3. Remove the window moulding. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(ref-204611) .
4. Remove the LH and RH sun visors. Remove the covers and the screws.
5. Remove the cowl vent screen. For additional information, refer to «FRONT END BODY PANELS»(ref-204605) .
6. Disconnect the audio antenna snap connector.
7. Remove the instrument panel defroster opening grille assembly. Disconnect the electrical connectors.
8. Disconnect the two heated wiper park grid electrical connectors. Release the wiring harness locators.
9. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld.
10. Using the special tool, starting at the top center of the windshield glass, cut the urethane adhesive away from the glass and work down the sides.
11. Remove the windshield glass assembly using a suitable suction tool.
12. Remove the dual lock windshield glass stops from the sheet metal frame.
13. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld.

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1. Dry fit the new windshield glass to the existing urethane bed on the adhesive area. Align the windshield in the opening for uniform fit.
2. Use tape or non-permanent marking pencil to make alignment marks on the windshield and the body to aid in the installation alignment of the new windshield.
3. After alignment, remove the windshield glass from the vehicle and place on a stable work surface.
4. Trim the remaining urethane adhesive on the pinch weld. The urethane must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.
5. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair the surface as necessary.
6. Use the wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSBM2G234- C to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry.
7. Install new the dual lock windshield glass stops.
8. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
9. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M5B280-C twice around the glass surface to be prepped.
10. Apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M2G314-B to the same area that was prepped in the previous step. Allow five minutes to dry.
11. Cut the urethane adhesive applicator tip to specification.
12. Apply a bead of Urethane Adhesive Essex 400-HV meeting Ford specification WSB-M2G316-B to the urethaned area.
13. Install the windshield glass on the vehicle, aligning it with marks made previously.
14. Check the windshield installation for air or water leaks through the urethane bead.
15. Place two strips of tape onto the windshield glass and secure it to the top of the windshield frame. This will help avoid misalignment while the urethane cures.
16. Connect the two heated wiper park grid electrical connectors.
17. Install the instrument panel defrost opening grille assembly. Connect the electrical connector.
18. Connect the audio antenna snap connector.
19. Install the rear view mirror. For additional information, refer to «REAR VIEW MIRRORS»(ref-204625) .
20. Install the LH and RH sun visors. Install the screws and covers.
21. Install the window moulding. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(ref-204611) .
22. Install the cowl vent screen. For additional information, refer to «FRONT END BODY PANELS»(ref-204605) .