Fulltext TSBs

Technical Service Bulletins

TSB
05-11-9
  • REMOVAL AND INSTALLATION OF REAR BOLT-IN GLASS – SERVICE TIP
Publication Date: May 25, 2005

FORD:
2001-2005 Explorer Sport Trac, F-150, Ranger

ISSUE:

Some 2001-2005 Explorer Sport Trac, Ranger, and F-150 vehicles may require replacement or re-sealing of the bolt-in rear glass. This TSB procedure supplements the Workshop Manual to prevent damage to the glass and body during removal, and leaks after installing glass. The 2006 Workshop Manual will be updated to incorporate these changes.

ACTION:

Use only a plastic tool to break the foam core butyl seal when removing the glass. When installing glass, use only 5/16″ (8 mm) foam core butyl for sealing. Refer to the following Service Procedure.

SERVICE PROCEDURE

GLASS REMOVAL

  1. Begin glass removal by following the procedure in the Workshop Manual, up to and including removing the attachment nuts.

    NOTE:THE BACK WINDOW GLASS HAS A FOAM CORE BUTYL PLACED ON THE RUBBER SEAL TO PREVENT LEAKS. THIS BUTYL SEAL MUST BE BROKEN TO REMOVE THE GLASS MODULE FROM THE BODY.

    NOTE:TO BREAK THE BUTYL SEAL USE ONLY A PLASTIC TOOL, REFERRED TO IN THE AUTOMOTIVE GLASS INDUSTRY AS A “PLASTIC WINDSHIELD SETTING TOOL” (FIGURE 1).




    Figure 1 – Article 05-11-9

  2. Slide the plastic setting tool under the window glass outside rubber seal between the attaching studs at one of the corners, to cut through the foam butyl. At the same time apply light hand pressure to the glass from the inside of the vehicle, pressing outward (Figure 2).


    Figure 2 – Article 05-11-9

  3. Once the glass module begins to separate from the body, continue to apply constant hand pressure from within the vehicle while moving around the perimeter of the glass. This will continue to break the foam core butyl seal. Once the seal is completely broken, the glass module may be removed.
  4. Remove any remaining foam butyl from the body and window rubber seal before glass installation.

GLASS INSTALLATION

NOTE:DO NOT USE A “SOLID TYPE” BUTYL OR URETHANE AND ATTEMPT TO ROLL IT TO MAKE IT ROUND, THIS WILL CREATE A LEAK. IT WILL ALSO MAKE THE NEXT GLASS REMOVAL EXTREMELY DIFFICULT.

  1. Apply the 5/16″ (8 mm) foam core butyl to the rear window glass rubber seal, starting at the bottom middle and working around.
  2. Overlap the foam butyl by 1″ (25 mm) at the starting/finishing points.
  3. Complete the installation by following the procedure in the Workshop Manual.
  4. Torque the attaching nuts to:
    • 2001-2003 F-150 27 lb-in (3 N-m)
    • 2004 F-150 Heritage 27 lb-in (3 N-m)
    • 2004-2005 F-150 35 lb-in (4 N-m)
    • Explorer Sport Trac 27 lb-in (3 N-m)
    • Ranger 18 lb-in (2 N-m)

PART NUMBERPART NAME
E69Z-19562-AFoam Core Butyl (25′ Roll) – Specification – WSB-M3G143-B (5/16″ or 8 mm)

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

DEALER CODING

BASIC PART NO.CONDITION CODE
70422B3007

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright 2005 Ford Motor Company