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48 AutoGlass™

Windshield

Removal

Remove the passenger-side wind-

shield wiper with a 14 mm socket and

ratchet. There is a spring-loaded

washer under the retaining bolt for

the wiper—remove it before you lift

the wiper off its mounting post.

Lift the hood to access the retaining

bolt for the driver-side wiper. Remove

the wiper with a 14 mm socket and

ratchet (remember the washer). Pull

the wiper off its mounting post.

Use a Phillips screwdriver to remove

the three retaining screws in the cen-

ter of the cowl. Then, using an angle

driver, reach the two Phillips screws in

the corners of the cowl. (These are

difficult to reach because they lie

under the corner of the hood.)

Peel off the hood’s rubber weather-

strip to expose five T30 torxs screws at

the bottom of the cowl—remove

them, then remove the cowl (which

comes out in two pieces).

Close the hood. The windshield has a

unique, three-component molding

system. If you’re careful, the rubber

molding along the roofline can be

removed undamaged and be reused.

The two plastic “A” pillar moldings

interlock with six metal clips attached

to metal studs along the inside edge of

each “A” pillar. These moldings are also

reusable, but be careful to avoid dam-

aging them or the mounting studs dur-

ing removal and reinstallation.

Using a small screwdriver, lower the

interior dome light. Pull off the two

electrical connectors for the light,

exposing two T25 torx screws;

remove them to lower the headliner.

Pull down the plastic trim cover for

the dome light. Using a small screw-

driver, release the locking clip for the

power connector for the sunroof, and

disconnect it.

Pop off the trim cover for the driver-

side sun visor retaining screws on the

left side. Remove the two Phillips

screws underneath to drop the visor,

and then release the wires for the van-

ity mirror light, and remove the visor.

Push in the release clip for the visor’s

locking clip, and pull it down from

the headliner.

Pull off the breakaway rear view mirror.

Repeat the same procedure to

remove the passenger-side sun visor.

Pull down the interior door weather-

strip and pop off the “A” pillar trim

panel with a panel removal tool. Use

the same procedure for both sides.

Lower the headliner and place a spacer

between it and the roof to allow for

clearance while cutting out the glass.

Use tape to mark the location of the

windshield setting blocks so you will

not cut them by mistake.

Place a protective cover over the

hood and dash to protect them. Tape

it in place on the dash, if necessary.

Note: Wear safety glasses and gloves

whenever you handle or cut glass.

Spray water between the pinchweld

and glass to help lubricate the cutting

surface.

Place an 8-inch blade on the glass

cutout knife and insert it in the

pinchweld at the top center. Cut

around the corner and down the pas-

senger side to the bottom.

Go back to the top center and cut

across the top, around the corner

and down the driver’s side to the

bottom corner.

Use an inflatable bag, like the

pumper, and lift the top of the glass.

This will give clearance to cut out the

bottom.

Caution: Don’t lift the glass too high;

this will cause excess stress, which

could break the windshield.

Be careful when cutting out the bot-

tom; there is a double band of ure-

thane at the bottom, and it may be

difficult to reach the bottom band.

After the urethane has been cut

loose, use a razor knife to release any

remaining stringers.

Lift the glass out of the pinchweld and

place it on a windshield stand to prep

it for reinstallation. Remove any dirt

or debris from the pinchweld with a

clean, lint-free cloth.

Note: Do not use any solvents—sol-

vents will contaminate the urethane

bond.

Installation

Use a razor knife to dress the pinch-

weld for installation of the new glass.

Trim the old urethane bead to approx-

imately 1 to 2 mm.

Brush away any debris after trimming

the old urethane. Use Essex U-413

pinchweld primer to cover any

scratches. Trim the old urethane

from the windshield, and then clean

the windshield with Essex glass

cleaner GC-800. Concentrate on the

outer edges where the urethane will

touch the glass. Dry set the wind-

shield, and mark it with tape.

Apply Essex U-401 glass prep on the

perimeter of the glass where it will

touch the urethane, and immediately

wipe it off. Repeat this procedure for

best results. Now apply Essex U-402

1999 Mercury Cougar

Editor’s Note: This windshield

installation is a remove and re-

install. If replacement is called

for, interior moldings may not

require removal.

Vital Info

1 2 3

1999 Mercury Cougar 1

Sommario

Pagina 1 - 1999 Mercury Cougar

48 AutoGlass™WindshieldRemovalRemove the passenger-side wind-shield wiper with a 14 mm socket andratchet. There is a spring-loadedwasher under the ret

Pagina 2

1998–99 Installation Guide 49glass primer to the same area.Reapply both beads of urethanealong the cowl edge of the wind-shield, and be sure to pla

Pagina 3

50 AutoGlass™Remove the 10 mm retaining bolt atthe back of the door glass—it goes allthe way through the glass and has aplastic sleeve around it to pr

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