Ford Falcon. Manual — part 426

501-11-6

Glass, Frames and Mechanisms

501-11-6

REMOVAL AND INSTALLATION (Continued)

3. Remove the rear quarter glass lower moulding.

Rear Door Quarter Window Glass —

Sedan

Removal

CAUTION: Gloves and protective eyewear

should be worn at all times.
1. Prepare to remove the rear door quarter 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.

2. Remove antenna terminal (left hand side only).

Item

Description

1

Door Outer Panel

2

Door Inner Panel

3

Seal Assembly

4. Open the liftgate and remove the quarter glass

rear moulding.

5. Grasp the rear glass upper moulding by hand and

carefully pull the moulding upwards to detach it

from the glass.

6. Make antenna terminal connection (left hand

glass only).

Item

Description

7. Prepare to remove the quarter glass by applying

1

Rear Door Quarter Window Glass

masking tape to the body in line with the glass

edges. This will help to protect the paintwork

2

Door Inner Panel

should the cutting tool used in removal slip or cut

3

Screw

through the urethane suddenly.

4

Rivet

CAUTION: When cutting near the corners

3. Cut the urethane around the perimeter of the

of the glass, cut inwards from the corners to

glass using a sharp, long-bladed knife. Remove

avoid bodywork damage.

glass and weatherstrip assembly.

Installation
1. Prepare surfaces and apply primer and sealer as

described in the windshield long or short

installation procedures.

2. Attach glass and weatherstrip assembly to door

by first locating the lugs on the lower part of the

moulding into the guides on the beltline.

3. Use duct tape or G-clamps to hold assembly to

door during curing period. (approx. 1.5 hours).

Rear Quarter Glass — Wagon

Removal

CAUTION: Gloves and protective eyewear

Item

Description

should be worn at all times.

1

Seal

1. Remove interior ‘C’ pillar trim. For additional

information refer to Section 501-05.

2. Remove two retaining nuts and remove exterior

‘C’ pillar trim.

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501-11-7

Glass, Frames and Mechanisms

501-11-7

REMOVAL AND INSTALLATION (Continued)

8. Cut the urethane around the perimeter of the

3. Prise the glass from the panel by cutting the

glass using a dual handle knife. Continue until all

butyl-coated PVC foam sealer.

urethane is cut. Thick areas of urethane not cut

by the dual handle knife can be cut with a utility

knife.

9. Attach suction cups to the quarter glass and lift it

clear of the aperture.
NOTE: Ensure that no urethane contacts silver

paint grid lines.

Item

Description

1

Rear Door Quarter Glass

2

Stud

3

Nut

4. Remove up butyl/foam from painted sheetmetal.
Installation

Item

Description

1. Remove the plastic release liner from the

butyl-coated PVC foam of the 6th Lite. Check that

1

Quarter Panel

the butyl covers the full length to be sealed.

2

Quarter Glass Assembly

2. Apply and tighten nuts to the five studs.

3

Urethane Sealer

3. Reinstall interior C-pillar trim.

Installation

Rear Door Quarter Glass — Ute

NOTE: For installation refer to the windshield long or

short installation procedures.

Removal

1. Install the rear quarter glass lower moulding.

CAUTION: Gloves and protective eyewear

2. Install the ‘C’ pillar trim panel.

should be worn at all times.

Rear Door Quarter Glass — LWB

1. Remove interior C-pillar trim. For additional

information refer to Section 501-05.

Removal

2. Remove antenna terminal.

CAUTION: Gloves and protective eyewear

3. Remove the two nuts from the studs.

should be worn at all times.
1. Remove interior C-pillar trim. For additional

information refer to Section 501-05.

2. Remove the five nuts from the studs.

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501-11-8

Glass, Frames and Mechanisms

501-11-8

REMOVAL AND INSTALLATION (Continued)

4. Prise the glass from the panel by cutting the

Item

Description

butyl-coated PVC foam sealer.

3

Glass and Clip Assembly Nut

4

Nut

5

Bolt

2. Raise the glass by hand and support the glass in

the fully raised position.

3. Remove the three nuts and three bolts attaching

the regulator to the inner panel.

4. The regulator assembly is a non-serviceable item

and must be replaced if faulty.

Installation
1. Position the regulator into the door and install the

retaining nuts and bolts.

2. Repeat steps 2-8 of Removal and Installation in

section Front Door Window Glass.

Item

Description

Rear Door Window Regulator

1

Glass Primer Urethane

2

Panel Assembly

Removal

3

Glass and Weatherstrip Assembly

1. Repeat steps 1-5 of Removal and Installation in

4

Lock Nut

section Rear Door Window Glass - Moveable.

5. Remove up butyl/foam from painted sheetmetal.

NOTE: Ensure that no urethane contacts silver

paint grid lines.

Installation
1. Remove the plastic release liner from the

butyl-coated PVC foam on the 6th Lite. Check that

the butyl covers the full length to be sealed.

2. Apply and tighten nuts to the two studs.
3. Connect

antenna

terminal.

4. Reinstall interior C-pillar trim.

Front Door Window Regulator

Removal

Item

Description

1. Repeat steps 1-5 of Removal and Installation in

1

Rear Door Inner Panel

section Front Door Window Glass.

2

Glass and Clip Assembly

3

Nut

4

Bolt

5

Rear Power Window regulator

2. Raise the glass by hand and support the glass in

the fully raised position.

3. Remove the bolts and nuts attaching the regulator

to the door inner panel and withdraw the regulator

assembly. The regulator assembly is a non

serviceable unit and must be replaced as an

assembly.

Installation
1. Position the regulator assembly into the door and

install the retaining bolts and nuts.

Item

Description

2. Repeat steps 2-6 of Removal and Installation in

1

Front Power Window Regulator

section Rear Door Window Glass - Moveable.

2

Front Door Inner Panel

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501-11-9

Glass, Frames and Mechanisms

501-11-9

REMOVAL AND INSTALLATION (Continued)

1. Place covers on vehicle fenders, seats and

Fixed (Stationary) Glass Replacement

instrument panel. Remove interior mirror.

2. Remove the wiper arm and blade assemblies. For

Special Tool(s)

additional information refer to Section 501-08.

BTB Glass Removal tool

3. Raise the engine hood and remove the cowl top

WK 10 HD

vent grille panel. For additional information refer

to Section 501-08.

4. Prepare to remove the windshield glass by

applying masking tape to the body in line with the

glass edges. This will protect the vehicle

paintwork should the cutting tool used in removal

slip or cut through the urethane.

CAUTION: Do not slam vehicle doors within

5. Cut paas moulding lip away level with edge of

24 hours of fixed glass replacement unless

glass.

vehicle windows are open 150mm. minimum.

Vehicles should not be driven until urethane

sealant has cured for a minimum of 6 hours.
NOTE: The stationary glass, which is bonded to the

body aperture flanges by urethane sealant, forms part

of the body structure. The replacement of any

stationary glass requires that urethane sealant be

used to maintain the integrity of the structure.

Stationary glass is fitted to:

Windshield (laminated with a tinted band).
Rear window glass - Sedan.
Liftgate glass - Wagon.
Rear door quarter glass - Sedan and Wagon.
Rear quarter glass - Wagon.

Two alternative methods may be used in the

replacement of stationary glass, depending on

certain criteria.

Short method

The short method is used where the original

urethane adhesive is retained on the body

opening flanges after the glass is removed

and serves as a base for the replacement

glass. The operator should remove the glass

ensuring the maximum amount of urethane is

retained on the body flanges. This method

may be used to replace cracked windscreens

or glass which is still intact.

Long method

In the long method, the urethane adhesive is

Item

Description

completely removed from the body aperture

1

Primer

flanges and replaced with new adhesive. This

method used where the adhesive cannot

NOTE: Width of primer at top edges of

serve as a base for the replacement glass or

windshield

body and paint repairs are required. All

2

Primer Overlap Area

remaining urethane adhesive must be

3

Paas Moulding

removed from the body aperture flanges.

NOTE: Width of primer along bottom edge

Front Windshield Glass

of windshield

4

NOTE: Width of primer at side edge of

Removal

windshield

CAUTION: Gloves and protective eyewear

5

Primer Overlap Area

should be worn at all times.

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