FORD MUSTANG 2003 Workshop Manual

Coupe
8. Remove the sun visors and clips zRemove the screws.
z Remove the clips.
9. Remove the roof side trim moulding. For additional information, refer to Section 501 - 08 .
10. Lower the front portion of the headliner.
All vehicles 11. Remove the two windshield wiper pivot arms. 1. Raise up on the pivot arms.
2. Release the retainer tabs, and release the windshield wiper pivot arms.
12. Remove the cowl grille weatherstrip. Klj . 3 ba
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13. Remove the cowl grille.
14. Using a soft brush or vacuum, clean any dirt or foreign material from the pinch weld.
15.
CAUTION: Cover the instrument panel to prevent possible damage.
CAUTION: Care must be taken to prevent scratching the pinch weld.
NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting.
Using the special tool, starting at the top center of the windshield cut the urethane adhesive
from the windshield glass and work down the sides.
16. Using the special tool, distance the windshield glass from the body. Klj . 4 ba
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17. Using the special tool cut the urethane adhesive and remove the windshield.
18. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
Installation
All vehicles
CAUTION: After installing the urethane installed windshield, the vehicle should not be
driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°
F) and relative humidity above 50% is 12- 24 hours (Refer to ESSEX drive away chart for cure
times as temperatures and humidity vary). Inadequate curing of the urethane adhesive may
adversely affect the strength of the urethane adhesive bond.
1. Dry-fit the windshield glass by centering it side- to-side and by adjusting the setting blocks (if
equipped) to get the correct position of the part top- to-bottom. Make alignment marks with tape
or non- staining grease pencil on both the glass and the vehicle body.
2. CAUTION: Care must be taken to avoid scratching the pinch weld.
Trim the remaining urethane on the pinch weld using only the full- cut method. in this method,
most of the existing urethane is removed leaving a level bead around the entire pinch weld. Klj . 5 ba
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3. Using a wool applicator, apply the Urethane Metal Primer Essex U-
413 meeting Ford
specification WSB-M2G234- C to any exposed metal on the pinch weld. Allow 6 to 10 minutes to
dry.
4. If reinstalling the original windshield glass, remove the excess urethane adhesive from the windshield glass.
5. If installing a new windshield glass, clean the inside of the glass surface with an alcohol- free
cleaner to make sure the ceramic- coated area is clean.
6. CAUTION: Wipe off the urethane glass prep immediately after each application
because it flash dries. Apply deliberate strokes, making sure not to overlap the applied
area.
If installing a new windshield glass, apply Urethane Glass Prep Essex U- 401 meeting Ford
specification WSB-M2G314- B twice around the class surface to be prepped.
7. If installing a new windshield glass, apply Urethane Glass Primer Essex U- 402 meeting Ford
specification WSB- M5B280-C to the same area that was in the previous step. Allow five minutes
to dry.
8. Cut the applicator tip to specification.
9. CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive
application, Urethane Adhesive Essex U- 216 meeting Ford specification WSB-M2G316- B
must be used due to its one hour cure time.
Apply a bead of Urethane Adhesive Essex 400- HV or Essex U-216 meeting Ford specification
WSB- M2G316- B to the pinch weld. Klj . 6 ba
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10.
CAUTION: Open a window to prevent the windshield glass from being pushed out
by air pressure when a door is closed.
Using the alignment marks install the windshield glass.
11. After the glass is set, check for water leaks and add urethane adhesive where needed.
12. Install the cowl grille.
13. Install the cowl grille weatherstrip.
14. Install the two windshield wiper pivot arms. zPosition the arms.
z Install the windshield wiper pivot arms.
15. Install the headliner.
Coupe 16. Install the sun visors and clips. Klj . 7 ba
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17. Install the roof side trim moulding. For additional information, refer to
Section 501 - 08 .
Convertible 18. Install the exterior A- pillar moulding and screw.
19. Install the weatherstrip retainers.
20. Install the weatherstrips.
21. Position the sun visors and install the screws. Klj . 8 ba
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z
Connect the electrical connector(s).
22. Install the visor trim moulding.
All vehicles 23. Install the RH and LH windshield side garnish moulding. zIf equipped with a convertible top, install the pin- type retainers.
24. Install the interior rear view mirror. Klj . 9 ba
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Klj . 10 ba
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REMOVAL AND INSTALLATION
Door Glass Run Retainer
Removal
1. Remove the door trim panel. For additional information, refer to Section 501 - 05 .
2. Remove the watershield.
3. Position the door window glass in the full up position.
4. Remove the nuts and the door glass run.
Installation 1. To install, reverse the removal procedure.
SECTION 501-
11: Glass, Frames and Mechanisms 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 501-
12: Instrument Panel and Console 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Bulkhead wiring harness electrical connector bolt 5 — 44
Floor console screws 2 — 18
Instrument panel support bolts 9 — 80
Instrument panel support nut 48 35 —
Intermediate shaft pinch bolt 47 35 —
Instrument panel reinforcement screws 9 — 80
Instrument panel steering column cover screws 9 — 80 Klj . 1 ba
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