Rear window glass (4-door) (Body and coating / Glass, frames and mechanisms / Ford Focus 1 1998-2004)

General equipment:

Hot air gun
Straight glazing knife for cutting glued glass
Direct Glazing Adhesive Kit
Direct Glazing Furnace
Glass suction cups

Removal

1. Remove the cap of the polyurethane (PU) glue tube and heat the PU glue for at least 30 minutes.

2. Remove the C-pillar trim panel. Refer to Section 501-05 for additional information.

3. Disconnect the rear roof trim from the roof panel.

Remove the roof trim retaining clips.

4. Place two blocks of suitable material between the roof sheathing and the roof panel as spacers.

5. Disconnect the electrical connectors of the rear window heater.

WARNING: Always wear gloves and goggles when using glass cutting tools as glass fragments may form during cutting. Wear ear protection when cutting. Failure to follow these instructions may result in personal injury.

CAUTION: Always replace the blade when changing the cutting depth to avoid damage to the body and trim panels.

NOTE: When cutting through the glass mounting studs, resistance may be felt at the bottom corners of the glass.

Cut through the PU adhesive with a suitable straight glazing knife and, with the help of another mechanic, use glass suction cups to remove the rear window glass.

Cut the PU adhesive from the inside of the vehicle to this maximum depth.
1. 30 mm
2. 25 mm

7. Remove the rear window glass seal.

Installation

1. Carefully remove the remaining mounting studs from the rear window glass flange.

2.

CAUTION: Do not touch the adhesive surface as this will disrupt the re-bonding.

Carefully trim the remaining PU adhesive from the rear window glass flange so that approximately 1mm of trimmed PU adhesive remains on the flange.

3. Inspect the rear window glass flange for any sheet metal damage, rust, or foreign objects that may or may cause glass damage.

4.

CAUTION: To ensure the PU adhesive cures, it is essential that all surfaces to be bonded are free of moisture.

Using a hot air gun, direct warm air (25°C) onto the rear window glass flange and glass bond line to remove all traces of moisture.

5. Prepare the glass, rear window glass flange and trimmed PU adhesive according to the instructions included with the PU adhesive kit.

6.

NOTE: Discard the first 100mm of PU adhesive as this adhesive may have a shorter open time.

NOTE: To avoid water leakage, an overlap of 20 mm must be provided at any interruption in the continuous strip.

Apply PU adhesive in a continuous bead 8 to 10 mm high to the rear window glass flange along the bonding line.

7. Install the rear window seal.

8. With the help of another mechanic, use glass suction cups to install the rear window glass.

Place the glass in the required position by pressing firmly and evenly.

CAUTION: During the curing of the PU adhesive, the door windows must be left open to avoid the increase in pressure when opening and closing the doors.

Using a suitable film, fix the rear window glass in the required position until the PU adhesive has cured.

10. If the ambient temperature drops below 10°C, use a hot air gun to continuously blow warm air (25°C) for 15 minutes (from inside or outside the vehicle).