Ford Focus manuals

Ford Focus Service Manual: Window Glass - Rear

Special Tool(s)

Deluxe Windshield Removal Tool 164-R2450 or equivalent

The Pumper
164-R2459 or equivalent

Material
Item Specification
Dow Urethane Adhesive Betaseal™ Express
Dow Urethane One Step Glass Primer Betaprime™ 5500 / 5500A / 5500SA
Sika Urethane Adhesive Sika Tack ASAP
Sika Urethane Metal and Glass Primer Sika 206 G+P
Ultra-Clear Spray Glass Cleaner ZC-23 ESR-M14P5-A


 
Item Part Number Description
1 5442006 Rear window glass

Removal

  1. Remove the parcel shelf. For additional information, refer to Section  501-05.
  1. Remove the 2 garment hangers and 2 pin-type retainers and release the rear of the headliner from the roof panel. For additional information, refer to Section  501-05.
  1. Place 2 blocks of suitable material between the headliner and the roof panel to act as spacers.
  1. Disconnect the 2 heated rear window glass electrical connectors.
  1. Before cutting the urethane adhesive, remove dirt and other foreign material from the pinch weld area.
    • Use a clean shop towel or oil-free compressed air.
  1. NOTE:

    Refer to manufacturer's instructions before using the Deluxe Windshield Removal Tool.

    Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting the urethane adhesive.

  1. WARNING: Always
    wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.

    WARNING: Wear
    protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.

    NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or otherwise damage the pinch weld during glass removal.

    NOTICE: Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels.

    NOTE:

    Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement rear window glass.

    NOTE:

    Some resistance may be encountered when cutting through the glass locating pegs in the upper corners of the glass.

    Insert the Deluxe Windshield Removal Tool at the upper center of the rear window glass and work toward the bottom corners.

  1. Using The Pumper, distance the rear window glass from the body.

  1. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive and remove the rear window glass and place on a stable work surface.

Installation

NOTE:

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

  1. Dry fit the rear window glass to the existing urethane adhesive on the body pinch weld.
    • Make alignment marks with tape or non-staining grease pencil on the rear window glass and the body to aid in the installation alignment of the rear window glass.
  1. Remove the rear window glass and place on a stable work surface with the interior side of the glass facing up.
  1. WARNING: Repair
    any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

    NOTE:

    Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.

    Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane adhesive on the pinch weld.

  1. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during glass removal.
  1. If installing the original rear window glass, remove the excess urethane adhesive.
  1. Clean the inside of the rear window glass with glass cleaner.
  1. NOTE:

    Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in this procedure.

    If installing a new rear window glass, apply glass primer according to the manufacturer's instructions. Allow at least 6 minutes to dry.

  1. Cut the urethane adhesive applicator tip to specification.

  1. NOTE:

    The rear window glass must be positioned within 10 minutes of applying the urethane adhesive.

    NOTE:

    Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and a continuous bead.

    Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the rear window near the center, making sure there are no gaps in the bead.

  1. WARNING: Do
    not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

    NOTICE: Before positioning the rear window glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.

    Using the alignment marks made previously, position the rear window glass on the pinch weld.
  1. NOTE:

    The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.

    After the urethane adhesive has cured, check the rear window glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.

  1. Position the headliner, install the pin-type retainers and garment hangers. For additional information, refer to Section  501-05.
  1. Connect the 2 heated rear window glass electrical connectors.
  1. Install the parcel shelf. For additional information, refer to Section  501-05.
Glass & Windows
...

Window Glass - Rear Quarter
Special Tool(s) Deluxe Windshield Removal Tool 164-R2450 or equivalent Pneumatic Knife with Offset Blade 107-R1511 or equivalent Material ...

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