2005 – 2007 Ford Mustang
Glassback Roof System
Installation Manual
Installation Manual Glassback Ford Mustang
Contents
Introduction 4
Cautions / Warnings: 4
Package Components: 5
Installation Tools and Materials (Not Included in Kit) 6
Disclaimer 7
Installation: 8
Installation Requirements: 8
Installation Steps: 8
Final Installation Pictures 16
Limited Warranty 16
Technical Assistance 16
Introduction
Introducing the all new Glassback Roof System designed exclusively for the Ford Mustang. This exciting new addition to the Webasto Product N/A Inc. line of products provides a completely new open top feeling without the inconveniences of a convertible.
A Sun Shade is not required as the glass comes standard with a solar absorbing, tinted, UV protected glass. (99% UVB protection)
Cautions / Warnings:
· Use safety glasses, skin protection and any additional safety equipment needed for hazardous materials handling and the use of power tools during installation process.
· Read and follow ALL material and tool cautions and precautions.
Package Components:
Glassback Roof Kit – P/N: 0511-7002-01a
Quantity/Description / Part#1-Glass Roof – Glass Only w/Frit / 0511-2800-01a
1-A-pillar Trim Driver Side / 0511-6401-13
1-A-pillar Trim Passenger Side / 0511-6402-13
1-C-pillar Trim Driver Side / 0511-6403-13
1-C-pillar Trim Passenger Side / 0511-6404-13
1-Front Trim / 0511-6400-10
1-Rear Trim / 0511-6405-10
1- Headliner – Charcoal Black / 115096
4-.060x.50 Urethane Bumper / 116095
4- .140x.50 Urethane Bumper / 116096
1- Roll ½”x.045 3M 2- Way Automotive Tape / 950012
1- Roof Cutout Template / 040906
Installation Tools and Materials (Not Included in Kit)
Tools/Supplies List for InstallationSika or CR Laurence urethane and primers may be used for Glassback Installation. Which ever products are most readily available.
NOTE: Only use products from one manufacturer per installation. Do NOT Combine chemicals.
Sika Industry: / CR Laurence Products:
Sikaflex 220+ / CRL900HV High Viscosity Urethane
Sika Primer 206 G+P / CRL9P Urethane Pinch Weld Primer
Sika Aktivator / CRL9GC Urethane Glass Primer
Sika Glass And Surface Cleaner / PWR22 Power Auto Glass Cleaner
Cotton Dauber / Cotton Dauber
Additional Tools And Supplies
T-20 Torx Bit / Electric Shears
T-25 Torx Bit / Protective Blanket
Screw Driver for Torx Bits / 1” Paint Brush
Straight Edge / Eye Protection
Pin Type Extractor Tool / Caulk Gun (Electric or Pneumatic Preferred)
Pneumatic Chisel / Scotch Brite Pad (Medium)
(6) 25 lb. Cloth Sand or Shot Bags / Masking Tape
2006-2007 Models Only: Foam or Comparable Material (Approx. 2’ thick) / Isopropyl (Rubbing) Alcohol
Lint-free cloth / 3M Automotive Adhesion Promoter 4298
Wax and Grease Remover
Disclaimer
Although Webasto has taken all reasonable care to ensure that the information contained in this Installation Manual (including, without limitation, references, databases, resources, specifications, illustrations and instructions) was accurate in all material respects at the time of publication, WEBASTO PROVIDES NO ASSURANCE, REPRESENTATION, WARRANTY OR GUARANTEE, expressed or implied (including third party liability), with regard to this Manual, including without limiting the generality of the foregoing, with regard to its accuracy, reliability or completeness. The entire information contained in this Installation Manual is provided by Webasto "AS IS" and without warranty of any kind, express or implied, including (but not limited to) any implied warranties of merchantability, fitness for any particular purpose, or non-infringement. Accordingly, by using the Glassback unit and this information, you agree that, to the greatest extent permitted by law, Webasto (including, without limitation, its subsidiaries, affiliates, agents, officers, directors, employees and insurers) is not and will not be liable for losses or damages resulting from this Installation Manual, its use, any information contained therein or the installation of the Glassback unit.
All product illustrations and specifications are based upon current information at the time of publication. Although descriptions are believed correct, complete accuracy cannot be guaranteed. Webasto reserves the right to make changes of any kind at any time, without notice or obligation, in the information contained on this Installation Manual. All data and information of any kind is subject to change without notice and Webasto assumes no obligation to update or correct information in this Manual.
As some states do not allow the exclusion or limitation of liability for consequential or incidental damages, the limitation contained herein may not apply to you. In such states, Webasto liability is limited to the greatest extent liability limitation is permitted by applicable law.
Installation:
Installation Requirements:
· Make sure the installation location will be available for a minimum of 24 hours at or above 60° F. This is the minimum allotted drying time needed before vehicle can be moved.
· Roll both windows down approximately 2” to prevent pressure build up inside vehicle during urethane curing time.
· Tape off upper A - C pillars and sill plates to prevent any damage during installation. Refer to corresponding pictures.
· All tools and products noted in this manual are required for installation. Do NOT use substitute materials and / or tools.
· Have a can of acetone available for potential spills and / or mishaps with the primer and urethane. Note that acetone works most effective if used immediately after incident.
· Have a can of Grease and Wax Remover available to clean up any excess 3M Adhesion Promoter from painted surfaces.
· Proper disposal of all hazardous materials used. I.e. used shop towels, daubers, paint brushes, etc…
Installation Steps:
Important: Begin installation with vehicle on level ground.
1 / Cover interior with protective blanket.2 / Remove both driver and passenger visors and visor arm clips using a T-25 bit.
3 / Remove overhead console. Overhead console is not fastened with screws, simply grab a hold of the housing and pull straight down to release. Unplug wire connector to overhead console.
4 / Remove the 2 push pin fasteners from rear of headliner. It is necessary to extract the center part of the fastener before it will release.
5 / Remove passenger A-pillar trim by pulling to release clips.
Note: Be careful of plastic tabs that lock into instrument panel. Refer to pictures.
6 / Using provided template (040906), Measure 6 ½” from rubber windshield seal to template and mark cut line on roof. Mark centerline on vehicle roof skin. Affix template to roof with masking tape.
Mark first side of hole and repeat above on the opposite side of roof skin by flipping template over.
7 / Remove the gutter rail trim and retaining clips as shown. Discard as these are no longer needed.
8 / Cut out roof skin around template. Start hole with an air chisel and finish cut with electric shears.
Note: This step will require two people; one to cut and the other to hold the scrap metal from falling inside the vehicle.
9 / Thoroughly scuff roof surface as shown with a Scotch-Bright pad.
Note: Do NOT go outside of the gutter rail channel. Only scuff inside the box shown in the adjacent picture.
Note: Factory Headliner is still in place.
New Picture→
If vehicle is equipped with pin striping on roof skin, ensure to completely remove it prior to scuffing roof surface.
10 / Clean roof with Isopropyl Alcohol to remove gross contamination (dirt/fingerprints/etc.) Allow time to air dry.
11 / Temporarily place front and rear trim on roof of car and mark the back edge of tape flange on the roof. Remove the trim pieces and place masking tape on these lines to prevent this area from being Aktivated and or Primed.
12 / Apply Sika Aktivator on roof structure with a lint free cloth. Wipe on, single wipe, not back and forth. Follow with a wipe off step with a clean lint free cloth. Allow Aktivator to cure for 10 minutes.
Note: The product flashes immediately and there will be no visible effect of wiping off, but it is a necessary step. This wait period is to ensure that the small amount of solids deposited has time to form a chemical bond with the surface.
13 / Apply a 1 ½” wide piece of masking tape around edge of Dot matrix pattern on Glassback ensuring the dots are completely covered. Clean glass with SIKA Glass Cleaner or CRL PWR Cleaner.
Note: Do not spin glass on cardboard box, as this may scratch the glass if foreign debris is present.
14 / Apply Sika Aktivator on glass outside of the taped off area with a lint free cloth. Wipe on, single wipe, not back and forth. Follow with a wipe off step with a clean lint free cloth. Allow Aktivator to cure for 10 minutes.
Note: The product flashes immediately and there will be no visible effect of wiping off, but it is a necessary step. This wait period is to ensure that the small amount of solids deposited has time to form a chemical bond with the surface.
15 / Apply SikaPrimer 206 G+P to roof structure with a clean brush, dauber, etc. Applied areas should not be re-coated with multiple coats. Avoid brushing back and forth over the wet film. Apply in one direction and slightly overlap passes if needed. Allow 10 minutes to dry.
Note: Open time for bonding to SikaPrimer 206 G+P is a minimum of 10 minutes after application, and a maximum 2 hours after application. If time exceeds 2 hours, the primer film can be “activated” by applying Sika Aktivator in a wipe on/wipe off method to the 206 G+P film to give an additional 2 hour period.
16 / Apply SikaPrimer 206 G+P to Glass.
17 / Scuff the tape flange of all trim pieces with ScotchBrite and clean thoroughly with Isopropyl Alcohol.
18 / Apply 3M Automotive Adhesion Promoter (4298) to all tape flanges and allow to dry.
19 / Tape all trim pieces. Press tape firmly on to trim.
Note: One large roll of ½” tape is provided in the kit, it is to be used on the A pillar trim, the C pillar trim and the rear trim. The rear trim piece has a 1” tape flange to allow for two rows of tape. The front trim piece requires a different tape that is a bit thicker and is 1” wide; it may or may not already be taped. If it is not taped, a small roll will be provided in the kit.
20 / Clean top surface of A-pillar to rear of C-pillar with Isopropyl Rubbing Alcohol.
21 / Apply 3M Adhesion Promoter to top edge of A and C pillars and allow to dry.
Note: Wax and Grease remover may be used to clean excess Adhesion Promoter.
22 / Install A pillar trim on both sides of car. Allow a small gap between the front fender and the A -pillar trim. Remove red backing and press trim powerfully to “wet out” the tape.
23 / Install C pillar trim on both sides of car. Remove red backing and press trim powerfully to “wet out” the tape.
24 / Remove masking tape at front and rear of roof.
25 / Apply 3M Adhesion Promoter on roof for front trim, allow to dry.
26 / Install front trim.
Note: Front edge of the front trim will be positioned between the rubber windshield trim and the front edge of the roof skin. Place 4” squares of acetate or similar material between roof skin and windshield trim, peel 2” of red backing from both ends of part, slide trim in to position, remove squares, finish peeling the red backing, and press trim powerfully to “wet out” the tape.
27 / Remove headliner from vehicle. With headliner lowered in vehicle remove dome light wire that is attached to headliner and remove headliner from car.
Note: Seats must be reclined and headliner removed via passenger doorway.
28 / Temporarily place rear trim on car and “dry fit” the glass. Determine the positioning of the rear trim, notice there is small amount of adjustment.
Note: A small gap between the trim and glass is ideal.
29 / Install rear trim. Peel red backing and press trim powerfully to “wet out” the tape.
30 / Dry fit glass once again. Place rubber bumpers on top of tape flange of front and rear trim to achieve a flush appearance. Remove glass from car.
31 / Preparing urethane tip before installing glass.
Cut the tip creating a ½” diameter hole or opening. Cut a V as shown approximately 3/8” in width by 5/8” – 3/4” in length.
When applying urethane, set tip directly on roof skin and allow the bead of urethane to exit via the previously cut “V”.
32 / Apply a continual bead of SikaFlex 220+ Urethane around the entire roof approximately 1/2” from the edge of the A-pillar trim, front trim, and rear trim. Apply a second bead approx. 1/2” from cut edge of sheet metal front and rear.
Caution: Make sure there are no gaps between the urethane start and stop points.
33 / Set glass panel on top of car applying pressure to glass. Shift glass to obtain consistent gaps as possible.
34 / Place 25lbs shot bags on glass where needed.
35 / Allow Urethane to cure overnight. (24 Hours)
36 / Install new headliner.
Note: Check fitment of headliner to the A pillar trim panel. If a gap is evident place a small foam “pusher” block behind the headliner.
Note: Waiting to install new headliner until just before vehicle delivery will prevent any unnecessary upward pressure during urethane cure time.
37 / Reinstall all interior parts in the reverse order ensuring to abide by all previously noted Precautions.
38 / Remove protective blanket and shot bags from vehicle.
Final Installation Pictures
See below for Final Installation Pictures.