Ford Mustang (1999-2004) Service Manual: Installation

Convertible

1. For installation of the back window glass, refer to Section.

Coupe

CAUTION: After installing the urethane installed back window glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13 C (55F) and relative humidity above 50% is 12-24 hours (Refer to ESSEX drive away chart for cure times as temperatures and humidity vary.). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond.

2. Dry-fit the back window glass by centering it side-to-side and by adjusting the setting blocks (if equipped) to get the correct position of the part top-to-bottom. Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body.

3. CAUTION: Care must be taken to avoid scratching the pinch weld.

Trim the remaining urethane adhesive on the pinch weld using only the full-cut method. In this method, most of the existing urethane is removed leaving a level bead around the entire pinch weld.

4. Using a wool applicator, apply the Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M234-C to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry.

5. If reinstalling the original back window glass, remove the urethane adhesive from the back window glass.

6. NOTE: If a new back window glass is to be installed, attach the new moulding to the edge of the glass starting at the top center then work down the sides and around the corners.

If installing a new back window glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.

7. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area.

If installing a new back window glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the class surface to be prepped.

8. If installing a new back window glass, apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was in the previous step. Allow five minutes to dry.

9. Cut the applicator tip to specification.

10. CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, Urethane Adhesive Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time.

Apply a bead of Urethane Adhesive Essex 400-HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld.

11. CAUTION: Open a window to prevent the back window glass from being pushed out by air pressure when the door is closed.

Using the alignment marks install the back window glass.

12. After the glass is set, check for water leaks and add urethane adhesive where needed.

13. Install the headliner.

14. Install the roof side trim moulding. For additional information, refer to Section.