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
Jamie Browning was the gold medalist in the 2009 Pilkington Classic
Auto Glass Technician Olympics.
© Copyright 2012 Key Communications Inc. All rights reserved.
No reproduction of any type without expressed written permission.