Volume 14, Issue 5 - September/October 2012

The Cutting Edge
new car installations

2012 Ford Fusion
by Jamie Browning


For vehicle and glass preparations please refer to AGRSS/ANSI 002-2002 as well as your adhesive manufacturer’s recommendations. Inspect the windshield for defects and any contamination that may compromise the bonding of the adhesive. Also look for any distortion, scratches or defects on the glass or moulding. Make sure to test the rain sensor before removal.

Remove the rearview mirror by using the appropriate method for either the top or bottom access mount mirror. Both will be removed by using a special removal tool, either from the top or bottom. Do not twist or pull downward on the mirror as this will cause the mirror to break. If the vehicle is equipped with a compass, make sure not to turn the key to the on position while the mirror is removed or you may be required to reset the compass. If the vehicle has a rain sensor, remove the cover and unplug the electrical connector. Next, lightly press the sensor and unclip the mounting hardware and gently remove from the windshield.

Ford states that the A-pillar trim panels are for “one time use” and should be replaced if removed. To remove the two wiper nuts, use an appropriate puller so you do not damage the wiper or motor. Next, remove the two retaining clips and the four pin-style retainers from the cowl panel. Remove the two nuts from the upper cowl grille and remove the cowl panel.

2. Removing the Windshield:
You can use a cold knife, power tool or wire for the sides and top of the windshield. For the bottom, a power tool or wire can be used. Keep in mind that there is no one correct method of removal. The technician should use the tool with which he feels most comfortable and the one that achieves a safe removal, both for the vehicle and the technician.

3. Preparing for the New Windshield:
Trim the existing urethane bead, leaving it 1 to 2 mm in height. Use your adhesive manufacturer’s pinchweld primer to prime all scratches if any exist and allow for proper drying according to your adhesive manufacturer’s recommendations. Please note that only the full-cut method is permitted by the AGRSS/ANSI 002-2002 standard.

4. Placement of the New Windshield:
Dry-fit the new windshield and mark it properly to ensure the correct setting procedure. Prepare the windshield according to your adhesive manufacturer’s recommendations, and then apply the adhesive and install the windshield. Ford recommends using a tip for the urethane that is cut at a 60-degree angle and is 8 mm wide and 16 mm tall. Make sure the deck height is correct and the markings on the windshield line up with those on the body that were applied during the dry set. Torque the cowl panel nuts at 10 Newton meters (Nm) or 89 lb. in. and the wiper arm nuts at 20 Nm or 177 lb. in.

5. Finishing Touches:
Install the cowl, wipers and mirror in reverse order from removal. Be sure to check the rain sensor, if equipped, as well as wiper operation before returning the vehicle to the owner. Check for any leaks and be sure to inform the vehicle owner of the safe drive-away time according to the adhesive manufacturer. Also be sure to record all lot numbers from the adhesive, VIN number and primers, as well as the DOT number from the windshield.

Jamie Browning was the gold medalist in the 2009 Pilkington Classic Auto Glass Technician Olympics.

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