2004 Ford Taurus By Gilbert R. Gutierrez

Transcription

1 2004 Ford Taurus By Gilbert R. Gutierrez Vehicle Information: Vehicle type: Four-door sedan. NAGS number*: Windshield part number is DW01528GBYN or TYN. The door glass is DD GTNN R-L. Rear-door glass is DD GTNN R-L. Quarter glass is DQ GTYN R-L; roof panel is DR09308YPYN; and back glass is DB10205GTYN (heated). time: Windshield, 3.3 hours; front door, 1.6 hours; rear door, 1.7 hours; quarter, 1.5 hours; roof, 0.9 hours; back, 1.9 hours. Technicians needed: One. Helpful tools or supplies: Retention tape or a rubber hose for the fenders and trunk lid. Angle screwdriver for the door panels. Watch for: Door panels can be easily misaligned and door-panel screws can be easily stripped. Make sure not to underdeck the windshield and back glass: this could lead to wind noise windshear if the glass doesn t fit properly. *With permission from the National Auto Glass Specifications 2004 Edition Fall Catalog and 2004 Fall Benchmark Calculator. Contact NAGS at 800/ or visit A. Windshield 1. Always wear eye and hand protection when working with glass. 2. Make sure that you have the right glass and that the urethane systems you are about to use are current. The windshield part number is DW01528GBYN or TYN. 3. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. 4. Remove the rearview mirror using a small screwdriver to release the standard break-away mirror. If you accidentally pull the mirror post from the ball joint, use a rearview-mirror assembly tool to put it back together. A4 5. Remove the windshield-wiper nut covers using an installation stick or small flat-tip screwdriver. 6. Remove the windshield-wiper nuts using a 15-millimeter wrench or socket. Push wiper arm downward so that the wiper will break loose from the wiper post. Wipers can sometimes be very hard to remove. To avoid stressing the post, use a wiper puller to help take the wiper off the post. 7. Five push-in clips hold the two-piece cowling at the bottom of the windshield. 8. After detaching the five push-in clips, raise the passenger-side cowling and disengage the four cowling fasteners on the underside of the cowling. Then, remove the cowling in an upward motion toward the windshield. 9. Next, remove the driver-side cowling in the same manner as on the passenger side. Remove the driver-side cowling second, so that you will not damage the cowling; a guide pin on the driver-side cowling keeps it in place on the body at the base of the windshield under the passenger-side cowling. 10. Cover the fenders with molding-retention tape or flexible rubber hose. 11. If you use a cold knife or power tool while working on this Taurus, remove the A-pillar trim panels because the windshield fits very close to the pinchweld. 12. Remove the weatherstrip from around the door jamb. 13. Remove the A-pillar trim panels by disengaging the trim panel from the A-pillar using a trim panel remover or installation stick. 14. Before beginning windshield removal, verify that the new windshield is the correct one and that urethanes and primers are up to date. 15. Make sure cutting blades are sufficiently sharp before use. 16. Before cutting out the windshield, take a few minutes to remove any type of contamination from the glass and pinchweld. This step will prevent contaminants from making contact with the urethane. 17. If using a cold knife, use a 3 4-inch cold knife blade. A7

2 A10 A12 You will either have to remove the top molding or try to get underneath it. Cut three sides and use a long knife or a power tool to cut the bottom of the windshield. 18. Note the gravity stops on this windshield. Mark their locations with pieces of tape or make a mark using a marker. This will keep you from hitting or cutting them during removal. 19. If trying to save the windshield, use an Equalizer with an 8-inch blade. When using an Equalizer, or any power tool, use plain water to lubricate the cutting area. Spray the top and sides, then make your cuts. 20. After cutting the sides and the top, place a Pumper in the top center of the windshield to open the cutting area on the bottom portion of the windshield. Never use your head as a pushing device, as this could result in back and neck injuries. 21. Spray the bottom of the windshield at least 4-to-5 inches above the urethane on the glass, so the water will flow down into the urethane while you are making your final cut across the bottom of the windshield. 22. Take the windshield out of the opening using a set of vacuum cups. Lift the glass and place it on a windshield stand or a suitable workstation. 23. After cutting the windshield out, remove contaminants such as dirt, moisture and other debris from the pinchweld. This would be a good time to clean the dashboard. 24. Dry fit the new glass to the opening. Mark your glass using a grease pencil or molding hold-down tape. 25. Place vacuum cups on the windshield in the appropriate location for a one-person set. 26. For driver-side setting of the windshield with a Glass Handler Kit, first place the kit s elbow-setting pad on the driver side of the cowl area, and then lift the windshield from the windshield stand using the vacuum cups. 27. Reaching over, place your elbow on the setting pad on the cowl area and set the windshield onto the old urethane. 28. With the windshield resting in the opening, make sure the windshield is in the right spot. 29. Adjust both sides to the correct setting, marking the passenger side and then the driver side. Lift the glass and place it on a windshield stand or a suitable workstation. 30. Follow the urethane manufacturer s recommendations for installation. Verify that the urethanes and primers are up to date. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers. 31. Clean the inside of the windshield using what the urethane manufacturer recommends, following its steps. Do not touch the windshield after cleaning it. 32. Remember to wear powder-free Nitrile gloves to keep from coming in contact with any chemicals. 33. Apply the glass prep following the urethane manufacturer s recommendations. Do not touch the windshield after prepping it. 34. Apply the glass primer following the urethane manufacturer s recommendations. Do not touch the windshield after priming it. 35. Using a pinchweld scraper, remove as much of the original urethane as the urethane manufacturer recommends. Before removing the old urethane, make sure there are no contaminants and do not touch the pinchweld after you have prepped the area. 36. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer. 37. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch with a Top Notch tool, cut the tip off of your nozzle with a nozzle cutter. With the cut nozzle, measure to the top of the roofline and, adding 1 16-inch higher than the roof line, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line and this will give you the appropriate triangular bead. 38. With the aid of vacuum cups, lift the windshield from the windshield stand or workstation. Reaching over, place your elbow on the setting pad on the cowl area and set the windshield on the urethane at the mark you made during your dry fit. Lower the driver side of the windshield onto the urethane and line up with the dry-fit mark; it is now in place. Continued on p. 61

3 A42 Continued from p The windshield is now ready to be decked. Press firmly to ensure a good seal. 40. Before reinstalling the parts, take a few minutes to check for leaks. Use a leak detector to go over the perimeter of the windshield. If you do find a leak, apply a little more pressure to the spot and ensure that the glass makes contact with the wet urethane. 41. Reinstall removed parts in reverse order. 42. Finish by attaching the rearview mirror to the new windshield with a rearview-mirror installer. 43. Allow the urethane to cure according to the urethane manufacturer s recommended cure time before returning the vehicle to the customer. Disregarding the safe drive-away times that your urethane manufacturer recommends could jeopardize the structural integrity of the car and the safety of its passengers. You have completed the removal and replacement of the windshield. B. Roof Panel 1. Make sure that you have the right glass. The roof part number is DR09308YPYN. 2. Open the roof-glass panel to align the mounting hardware so that the glass panel is to the outer opening of the roof. 3. Remove the two No. 2 Phillips screws from one side of the glass panel on the railing hardware, then B3 remove the two No. 2 Phillips screws on the opposite side. 4. Lift the glass from the front side, sliding out from the opening. Replacement 5. If the roof panel was broken, make sure there are no broken pieces of glass or any other debris. 6. Take a good look at the railing to make sure there is enough lubricating grease on the rails so that the glass will function properly. If not, take a small amount of grease and make sure the rails are ready for the glass. 7. Reinstall the glass from the front side, sliding the glass back into the opening. 8. Align the glass-panel hardware and the hardware on the railing. 9. Replace the four No. 2 Phillips screws. 10. Check the operation of the glass by opening and closing the roof panel several times. 11. You have completed the removal and replacement of the roof panel. C. Front-Door Glass and Replacement 1. Make sure that you have the right glass. The frontdoor glass part number is DD GTNN. 2. Remove the two No. 2 Phillips screws from the armrest pull handle. 3. Remove the five No. 2 Phillips screws from around the side and the bottom of the panel. The screw at the front of the panel can be easily removed using an angle screwdriver. 4. Remove the door panel by pulling it in an outward motion, disengaging the eight door clips around the door panel. The clips start about 5 inches down from the side and go all around the panel. Gently pull the door panel. 5. Remove the mirror-trim panel plug that covers the 6-millimeter bolt by using a small flat-tip screwdriver. 6. Next, remove the second 6-millimeter bolt from the lower part of the mirror-trim panel. 7. Disengage the three electrical harnesses that power mirrors, locks and door glass. 8. Remove the door panel and set in a safe place. 9. Remove the interior plastic beauty ring from the interior of the door frame. 10. Remove the weatherstrip from the interior of the door. 11. Lower the glass to align the mounting hardware to the openings. 12. Punch out the two rivets that hold the glass to the carriage, using a rivet-stem remover. 13. Drill off the rivet head. 14. Lift the glass out by lifting the back side of the glass first to disengage it from the carriage. 15. To replace the door glass, slip the glass back into the door in the same manner as you removed it. Make sure it is fully in the carriage and aligned before riveting the two long rivets. 16. Be sure to check the operation of the glass before

4 D9 E3 C12 replacing the panel to ensure that it operates properly. 17. Reinstall the parts in reverse order. 18. Check the operation of the glass again by rolling up and down several times. 19. You have completed removal and replacement of the front-door glass. D. Rear-Door Glass and Replacement 1. Make sure that you have the right glass. The reardoor glass part number is DD GTNN. 2. Remove one No. 2 Phillips screw from the arm-rest pull-handle well. 3. Remove the three No. 2 Phillips screws from around the side and the bottom of the panel. 4. Remove the door panel by pulling in an outward motion, disengaging the eight door clips around the door panel. The clips start about 5 inches down from the side and go all around the panel. Gently pull the door panel. 5. Disengage the electrical harness that powers the door glass. 6. Remove the door panel and set in a safe place. 7. Remove the interior plastic beauty ring from the interior of the door frame. 8. Remove the weatherstrip from the interior of the door. 9. Lower the glass to align the mounting hardware to the openings. 10. Punch out the two rivets that hold the glass to the carriage, using a rivet-stem remover. 11. Drill off the rivet head. 12. Lift the glass out by lifting the back side of the glass first to disengage from the carriage. 13. To replace the door glass, slip the glass back into the door in the same manner as you removed it. Make sure it is fully in the carriage and aligned before riveting the two long rivets. 14. Be sure to check the operation of the glass before replacing the panel to ensure that it operates properly. 15. Reinstall the parts in reverse order. 16. Check the operation of the glass again by rolling up and down several times. 17. You have completed the removal and replacement of the front-door glass. E. Quarter Glass 1. Make sure you have the right glass. The quarterglass part number is DQ GTYN. 2. Remove the weatherstrip from around the door jamb. 3. Remove the interior trim panel with an installation stick or panel remover. There are four push-in fasteners. 4. Unbolt the three 10-millimeter bolts that hold the quarter glass. Push the glass with glove-covered hands, with a steady outward force, to release the glass from the foam core. 5. After removing the old quarter glass, remove contaminants such as dirt, moisture and other debris from the pinchweld. 6. Be sure to remove the paper protector from the foam core. 7. Lift the quarter glass from a suitable workstation, using your vacuum cups. 8. Set the quarter glass in the opening, make sure the studs are completely through the holes and then press the glass in place. 9. The quarter glass is now ready to be decked. Press firmly to ensure a good seal, and re-install the bolts.

5 10. Reinstall removed parts in reverse order. 11. You have completed removal and replacement of the quarter glass. F. Back Glass 1. Make sure you have the right glass. The back-glass part number is DB10205GTYN. 2. Remove the interior trim panel with an installation stick or panel remover. There are four push-in fasteners. 3. Disconnect the electrical tabs on the heated back glass. 4. If trying to save the back glass, use an Equalizer with an 8-inch blade and make sure the unsharpened side is facing the body of the car. 5. Wrap the sheath of your Equalizer with about six turns of duct tape to create a gap between the glass and the blade. This gap will ensure the removal of the glass without damaging the under-seal molding. 6. When using an Equalizer, or any power tool, use plain water to lubricate the cutting area. Spray the top and sides, then make your cuts. 7. Spray the bottom of the back glass at least 4-to-5 inches above the urethane on the glass, so the water will flow down into the urethane while you are making your final cut across the bottom of the back glass. 8. Take the back glass out of the opening using a set of vacuum cups. Lift the glass and place it on a windshield stand or a suitable workstation. 9. After cutting the back glass out, remove contaminants such as dirt, moisture and other debris from the pinchweld. This would be a good time to clean the rear deck. 10. Make sure to dry fit the new glass to the opening. Mark your glass using a grease pencil or molding holddown tape. 11. Place vacuum cups on the back glass in the appropriate location for a one-person set. 12. For driver-side setting of the back glass with a Glass Handler Kit, first make sure to tape the trunk lid halfway open, then lift the back glass from the windshield stand using vacuum cups. 13. Reach over and set the back glass onto the old urethane. 14. With the back glass resting in the opening, make sure it is in the right spot. 15. Adjust both sides to the correct setting, marking the passenger side and then the driver side. Lift the glass and place it on a windshield stand or a suitable workstation. 16. Follow the urethane manufacturer s recommendations for installation. Verify that the urethanes and primers are up to date. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers. 17. Clean the inside of the back glass using what the urethane manufacturer recommends and following its steps. Do not touch the back glass after cleaning it. 18. Remember to wear powder-free Nitrile gloves to keep from coming in contact with any chemicals. 19. Apply the glass prep following the urethane manufacturer s recommendations. Do not touch the back glass after prepping it. 20. Apply the glass primer following the urethane manufacturer s recommendations. Do not touch the back glass after priming it. 21. Using a pinchweld scraper, remove as much of the original urethane as the urethane manufacturer recommends. Before removing the old urethane, make sure there are no contaminants and do not touch the pinchweld after you have prepped the area. 22. Apply the pinchweld primer only to the areas where it is needed, and follow the urethane manufacturer s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer. 23. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch with a Top Notch tool, cut the tip off of your nozzle with a nozzle cutter. With the cut nozzle, measure to the top of the roof line and, adding 1 16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line and this will give you the appropriate triangular bead. 24. With the aid of the vacuum cups, lift the back glass from the windshield stand or workstation. Reach over and set the back glass on the urethane at the mark you made during your dry fit. Lower the driver side of the back glass onto the urethane and line up with the dry-fit mark; it is now in place. 25. The back glass is now ready to be decked. Press firmly to ensure a good seal. 26. Before reinstalling the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you do find a leak, apply a little more pressure to the spot and ensure that the glass makes contact with the wet urethane. 27. Reinstall the removed parts in reverse order. 28. Allow the urethane to cure according to the urethane manufacturer s recommended cure time before returning the vehicle to the customer. After the urethane has cured, release the car to your customer. To disregard the safe drive-away times that your urethane manufacturer recommends could jeopardize the structural integrity of the car and the safety of its passengers. 29. You have completed the removal and replacement of the back glass. The author is product sales director and senior technical advisor for Equalizer Industries Inc. in Round Rock, TX. Car provided by Mac Haik Ford, Lincoln and Mercury dealership in Georgetown, TX.