Ford Falcon. Manual — part 427

501-11-10

Glass, Frames and Mechanisms

501-11-10

REMOVAL AND INSTALLATION (Continued)

6. Clean glass thoroughly to allow visibility of the

Short Method

cutting operation, and trim excess sealant

1. Trim the urethane sealant bed on the windshield

material from the edge of glass using a suitable

aperture flange until it is relatively smooth, and

blade.

remove any loose urethane pieces. Exposed body

7. Use BTB glass removal air tool (Part no:WK 10

surfaces should be cleaned with X55 solvent (or

HD). Spray into the flange from outside, & as

equivalent) and primed with urethane primer.

close as possible to the urethane from inside. Use

a combination of Baby shampoo & water as this

will not stain IP etc. This aids the cutting tool to

slide through the urethane. Cut the Sides & Top

externally using 90

° external blade.

Then using the long flat blade from inside the

vehicle cut away the Bottom & Free top corners.

Take care not to demage sheet metal & the IP

Top as it is not replacable.

8. When cutting operation is completed (be sure

there are no areas where sealant is still attached

to glass, as one such hold-up will cause breakage

of the windscreen on removal) attach suction cups

to glass and lift clear of aperture.

WARNING: Be careful not to damage IP

top surface (not replaceable).

Installation
NOTE: Determine which installation method is

appropriate under the circumstances. Refer to the

criteria for each method given earlier on this page.

Item

Description

1

Glass asy. windshield

2

Paas moulding

3

Urethane sealant

2. Apply urethane sealant to exposed areas to

achieve an even sealant bed.

3. Clean periphery of glass with urethane cleaner

(ESB M5B 280 A or equivalent). Wipe cleaner off

immediately.

4. Apply urethane glass primer to the glass surface

ensuring no light is visible through the primer.

Allow the primer to cure.
NOTE: Thoroughly shake and stir the urethane

glass primer to ensure uniform pigment mixing

prior to application.

5. Apply a 13-15 High X 9-11 Wide triangular bead

of urethane sealant to the primed surface of the

glass for the entire perimeter. Ensure it is

positioned within the sealant areas shown.

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501-11-11

Glass, Frames and Mechanisms

501-11-11

REMOVAL AND INSTALLATION (Continued)

6. Attach suction cups to the windshield glass and lift 11. Assemble the interior rear view mirror to the

into position on primed body flange.

bracket and tighten the mirror retaining grub

screws.

NOTE: Glass must be centred in windshield

opening so the side clearances vary by not more

Installation

than 3mm.

Long Method

1. Clean all hardened Urethane from the flange.

Remove all dirt, dust etc. and clean flanges with

X55 solvent or equivalent to remove grease etc.

Wear light cotton gloves to avoid finger prints and

apply cleaner with a lint free cloth.

2. Using a clean brush, apply urethane body primer

to the flanges ensuring that no paint is visible

through the primer. Overlap primer in bottom LH

and RH corners. Primer application is sufficient

when appearance is glossy and free of streaks.

Allow 30 minutes for primer to cure.
NOTE: Do not touch primed surfaces or allow

surfaces to be contaminated prior to glass fitment.

3. Clean all dirt, dust etc. from windshield glass inner

surface.

4. Using a lint free cloth wipe the outer 25mm. of

inside windshield perimeter with urethane glass

cleaner.
NOTE: Remove glass cleaner immediately after

application because it flash dries.

5. Using a clean brush, apply urethane glass primer

to the glass surface with no light visible through

the primer. Allow to dry for 5 minutes.
NOTE: Thoroughly shake and stir the urethane

glass primer to ensure uniform pigment mixing

prior to application.

6. Apply a bead of urethane sealant around the

perimeter of the glass on the primed surface. The

sealant bead should be approximately 13-15. high

Item

Description

with a base width of 9-11mm. and triangular in

1

Rear door fixed glass

shape.

2

Screw

7. Attach suction cups to the windshield glass and lift

3

Bolt

into position on primed body flange. Use the

4

Rear door

locating pins to position the glass.

5

Rivet

NOTE: If any primer and/or urethane adheres to

the body or trim, other than where required, it

7. Secure the windshield by pressing upward until

must be removed immediately or the surface may

the upper moulding is firmly contacting the roof

be damaged if removed when dry.

rebate.

8. Position the wiper arm and blade assemblies and

NOTE: If any primer and/or urethane adheres to

install the retaining nuts.

the body or trim, other than where required, it

must be removed immediately or the surface may 9. Install the cowl top grille panel support brackets.

be damaged if removed when dry.

10. Position the cowl top grille panel and install

attaching screws.

8. Position the cowl top grille panel and install

attaching screws.

11. Attach the interior rear view mirror bracket to the

windshield in position as shown in Figure using

9. Position the wiper arm and blade assemblies and

the Motorcraft Adhesive Kit or equivalent.

install the retaining nuts.

12. Assemble the interior rear view mirror to the

10. Attach the interior rear view mirror bracket to the

bracket and tighten the mirror retaining grub

windshield in position as shown in Fig. 20 using

screw.

the Motorcraft Adhesive Kit or equivalent.

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501-11-12

Glass, Frames and Mechanisms

501-11-12

REMOVAL AND INSTALLATION (Continued)

13. Clean windshield, remove covers from fenders,

seats and instrument panel.

Rear Windshield Glass — Sedan

Special Tool(s)

BTB Glass Removal Air Tool

WK 10HD

NOTE: The rear windshield glass is bonded to the

moulding and the two cannot be separated.
The moulding will be damaged during the removal

process and therefore the glass and mouldings

assembly cannot be re-used. Remove Roof Ditch

Mouldings to avoid damage.

Removal

CAUTION: Gloves and protective eyewear

should be worn at all times.
1. Place covers on the rear parcel shelf, seats and

rear quarter panels.

2. Remove the heated rear glass wiring connectors.
3. Remove rear interior trim panels surrounding rear

windscreen. For additional information refer to

Section 501-08.

Item

Description

4. Prepare to remove the rear glass by applying

1

Rear Windshield

masking tape to the body in line with the glass

2

Paas Moulding

edges. This will help to protect the vehicle

3

Urethane Sealant

paintwork should the cutting tool used in removal

slip or cut through the urethane.

5. Use a lubricant such as Baby shampoo & water

applied inside the flange to aid air tool to slide

CAUTION: When cutting the urethane

when cutting urethane. Use glass removal air tool

near the corners of the glass, cut inwards

to cut all four sides around the perimeter of the

from the corners to avoid vehicle bodywork

glass, externally using external blades. Free top

damage when cutting from inside. Be carefull

corners using long flat blade & cut from inside the

not to demage sheet metal.

vehicle.

6. Attach suction cups to the rear glass and lift it

clear of the aperture.

Installation

For installation procedures refer to the windshield long

or short installation procedures. And also follow these

steps:
1. Urethane bead 9-11 wide and 12-14 high.
2. Make electrical connection from rear glass.

Fly-Lead to aerial amplifier module box on left

hand side.

3. Make electrical connection from earth lead to

glass terminal left hand side.

4. Because it will effect on glass antenna

performance.
NOTE: Ensure that no urethane contacts silver

paint grid lines.

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501-11-13

Glass, Frames and Mechanisms

501-11-13

REMOVAL AND INSTALLATION (Continued)

4. Cut around the perimeter of the glass using a dual

Liftgate Glass — Wagon

handle knife. Continue until all urethane is cut.

Thick areas of urethane not cut by the dual

Removal

handle knife can be cut with a utility knife.

CAUTION: Gloves and protective eyewear

should be worn at all times.
1. Remove liftgate wiper arm and blade.
2. Remove the heated rear glass wiring connectors.

NOTE: The PCV perimeter moulding is bonded to

the glass and must be replaced as part of the

liftgate rear glass assembly.

3. Prepare to remove the liftgate rear glass by

applying masking tape to the body in line with the

glass edges. This will help to protect the vehicle

paintwork should the cutting tool used in removal

slip or cut through the urethane.

CAUTION: When cutting near the corners

of the glass, cut inwards from the corners to

avoid bodywork damage.

Item

Description

Item

Description

1

Liftgate outer panel

1

Rear Windshield

2

Liftgate inner panel

2

Glass Prier - Urethane

3

Nut

3

Glass Cleaner - Urethane

4

Urethane Sealer

5. Attach suction cups to the liftgate glass and lift it

clear of the aperture.

Installation
NOTE: For installation, refer to the windshield long or

short installation procedures, followed by assembly of

four retaining nuts.

1. Reconnect the liftgate rear heated glass wiring

connectors.

2. Refit the liftgate wiper arm and blade.

Rear Windshield Glass — Ute

Removal
NOTE: The rear windshield glass is bonded to the

moulding and the two cannot be separated.

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