OEM 2002 Mercury Cougar Windshield

2002 Mercury Cougar Windshield Parts Questions & Experts Answers

• Q: How to service and repair a windshield on 2002 Mercury Cougar?

  A: The repair and service procedure starts with disconnecting the battery ground cable then applying heat to the PU adhesive according to its ambient temperature status. If temperature remains below 10°C the adhesive needs to receive heat by placing cartridges on a heated radiator or using a hot air gun set to 25°C for 15 minutes. Start by taking off the cowl panel weather strip then proceed to remove windshield wipers by raising the wiper arm covers followed by unmounting the wiper nuts and removing washers and wiper arms and the cowl grille panel after which you should detach the side and top windshield weather strips and the A-pillar trim and sun visor screws and sun visor clip by disconnecting the pin and unclipping the accessory. The front portion of the headliner needs a small suitable spacer block for detachment followed by removing the rear view mirror. The windshield requires a pneumatic knife with 28 mm hooked blade for its perimeter cut while the bottom edge requires a 60 mm hook blade for the procedure. Cut the PU adhesive edges on top and sides of the interior with the interior auto glass cut-out knife and its four-inch blade after applying EC7784 lubricant or water and soap (10:1 ratio) across the adhesive surface. The blade for the heated windshield reinstallation must maintain a low position around the heated connectors. You need assistance from another technician to remove the windshield using suction pads after making the bottom cut with an eight-inch cutter blade attached to the auto glass cut-out knife. Before installing the windshield remove sufficient PU adhesive away from the opening so it remains at 1 mm thickness on the bodywork surface while inspecting the pinch weld sealing area for signs of damage or foreign contaminants. Control the temperature of blown air at 25°C to dry the windshield opening as well as the glass bond line and verify complete dryness of all bonding surfaces. Starting from the first 100 mm discard adhesive but use a smooth continuous 8 to 10 mm height bead of PU adhesive while overlapping each break by 20 mm to stop leaks according to the adhesive kit instructions before proceeding with prepared glass windshield opening and trimmed PU adhesive. Two technicians should work together to install the windshield while applying warm air consistently for 15 minutes if outside temperature stays below 10°C. The installation process concludes by reattaching the rear view mirror and removing the headliner spacer before installing the sun visor clip with the pin followed by A-pillar trim panels and windshield top and side weather strips before cowl grille panel installation along with windshield wipers and cowl grille panel weather strip and grounding the battery cable.