Windshield Glass: Removal

WARNING: This page is about a different car, the 2005 Mercury Mountaineer, 2005 Ford Explorer, 2004 Mercury Mountaineer, and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting and removing the glass from the vehicle.

Remove the RH and LH side a-pillar trim panels. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
Remove the sun visors and retainers and, if equipped, the overhead console. For additional information, refer to INSTRUMENT PANEL AND CONSOLE .
If equipped, remove the roof opening panel trim.
Remove the interior mirror. For additional information, refer to REAR VIEW MIRRORS .
Lower the front portion of the headliner.
If equipped, disconnect the heated windshield electrical connectors.
Remove the wiper pivot arms. For additional information, refer to WIPERS AND WASHERS .
Remove the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
Remove the windshield glass moulding assembly.

NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting.

Fig 1: Cutting Urethane Adhesive From Windshield Glass

Courtesy of FORD MOTOR CO.

Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and working toward the bottom corners.
Using the special tool, distance the windshield from the body.

Fig 2: Identifying Distance Of Windshield From Body
Courtesy of FORD MOTOR CO.

NOTE: Removing the windshield glass requires more than one technician.

NOTE: Be sure not to scratch the pinch weld while removing windshield glass.

Fig 3: Cutting Remaining Urethane Adhesive

Courtesy of FORD MOTOR CO.

Using the special tool, cut the remaining urethane adhesive and remove the window glass.
Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.