November/December  2001

The Cutting EDGE
    new car installations

2002 Mercury Mountaineer

1. Getting started:
In preparation for the windshield replacement, always remember to protect the surfaces of the vehicle that could cause damage. Remove the rearview mirror, which has an auto dimmer attached. Remove the wipers by lifting up on the wiper arm and sliding out the lock to take off the tension. Remove the cowl by prying upwards with a door-pad tool. The cowl is held in position with spring clips—like the ones in the older-style Ford Explorer. This new vehicle has a much larger cowl and goes under the hood area unlike the older one. This will expose the bottom of the windshield. As with the previous Explorer, the windshield has a three-sided wraparound moulding that comes with the new windshield.

2. Removing the original windshield:
We recommend using the full cut-out method. Using a sharp chisel or utility knife, remove the adhesive, leaving a thin skin of well-bonded urethane on the pinchweld. Be careful not to disturb the body paint. This windshield can be removed with a power tool or cold knife. With the cold knife, simply cut the outside edge of the moulding off with a utility knife to allow access with the cold knife.

3. Preparing for the new windshield:
Prime the pinchweld according to your adhesive manufacturer’s specifications. Concentrate only on any areas of the paint that may have been scratched or damaged during the removal process. Also prime any areas outside the original bond line that may need priming. The freshly cut urethane bed provides the best bonding surface. Allow proper time for the primers to cure. Clean and prime the windshield according to the adhesive manufacturer’s recommendations.

4. Placement of the new windshield:
Dry-set the windshield into the opening, being sure to properly adjust for proper alignment. Remove the windshield and set it on a cradle with the inboard lite in the upright position. Use a properly cut V-notch tip to duplicate the original bead size. Apply a high-viscosity, two-part adhesive to the glass. Set the windshield into the opening using your dry-set marks for proper alignment, being careful not to slide the windshield once it makes contact with the pinchweld. The new windshield will be bonded with the new moulding.

5. Finishing Touches:
Clean and prep the vehicle. Replace the cowl panel by snapping it back into place. Replace the wipers and release the tension lock. Replace the mirror. Perform the leak test, check wiper operation and then clean and detail the vehicle.

Reports from the field

Always wear eye, hand and wrist protection while working on the vehicle. This vehicle is equipped with dual airbags and will require additional cure time before releasing vehicle to the owner. We recommend rapid-curing, two-part, high-viscosity urethane for passenger-side airbag-equipped vehicles. Inform the vehicle owner of the cure time and any other additional precautions before installation. Always return the vehicle to manufacturer’s specifications. Protect all interior and exterior portions of vehicle to prevent any damage. Protect all interior areas, seats, dash and also the exterior fender areas. 


This info is reprinted from TechPoints, a bi-monthly newsletter available from Performance Achievement Group, an auto glass training company in Madison, Wis. 


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