21S42 – Inadequate Panoramic Roof Glass Panel Bonding – 2021 Mustang Mach-E

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September 14, 2021 NHTSA CAMPAIGN NUMBER: 21V712000

Inadequate Panoramic Roof Glass Panel Bonding

A roof panel that separates from a vehicle can become a road hazard, increasing the risk of a crash or injury.

 

NHTSA Campaign Number: 21V712

Manufacturer Ford Motor Company

Components VISIBILITY

Potential Number of Units Affected 13,544

 

Summary

Ford Motor Company (Ford) is recalling certain 2021 Mustang Mach-E vehicles. The vehicle’s panoramic roof glass panel may not have been properly bonded to the vehicle, which could allow it to detach.

 

Remedy

Dealers will apply additional urethane adhesive, free of charge. Owner notification letters were mailed October 29, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 21S42.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


2021 Ford Mustang Mach-E
2021 Ford Mustang Mach-E

 


AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Mustang Mach-E 2021 Cuautitlan February 24, 2020 through June 18, 2021

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the urethane adhesion of the panoramic roof glass panel to the vehicle body structure may be inadequate.  If affected, the roof glass may loosen and could become detached from the vehicle presenting a road hazard. Customers may also experience increased wind noise and water leaks.

 

SERVICE ACTION

Parts Availability – Prior to scheduling customer for repairs, ensure the foam seal required for the panoramic roof glass is on site at your dealer. LJ8Z-19B822-AA is expected to start shipping by the end of November 2021.

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to reseal the panoramic glass roof. This service must be performed on all affected vehicles at no charge to the vehicle owner.

NOTE: The vehicles in this program also require 21C22 be performed. Check OASIS to confirm FSA 21C22 is open, and if so, refer to the technical instructions to perform both 21C22 and 21S42 as a combined repair procedure.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owners were mailed letters the week of October 25, 2021, informing them repair instructions and parts ordering information are anticipated to be available to dealers on November 15, 2021.

Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. 

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this compliance recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicles.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

 

OWNER REFUNDS

Refunds are not approved for this program.

 

RENTAL VEHICLES

Dealers are pre-approved for up to 2 days for a rental vehicle. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the day(s) the vehicle is at the dealership for part replacement. Prior approval for more than 2 rental day(s) is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for consideration and approval if appropriate.         

 

PICKUP AND DELIVERY

2021 Mustang Mach-E customers affected by this recall have the option of complimentary Vehicle Pickup & Delivery service (at participating dealers) with a rental for up to 2 days. Claim any additional rental days approved by the SSSC as instructed.

Dealers are authorized to claim unique services for completing this program, including:

  • Dealers are authorized to claim one-half labor hour per repair for vehicle pick-up and delivery services.
  • Dealers must retain a Vehicle Pick-up and Delivery Record with the repair order documentation. Refer to the Claims Preparation and Submission section and Attachment IV for details.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number Description Order Quantity Claim Quantity
LJ8Z-19B822-AA Panoramic foam seal 1 1
Consumables Required for all Vehicles
Obtain Locally Masking Tape Claim as MISC OTHER
Glass Cleaner
Dow BETAPRIME 5504G / Sika Primer-207 or equivalent
SikaTack MACH 60 / SikaTack MACH 30 /

Dow BETASEAL Express / Sika Tack ASAP

Urethane Adhesive or equivalent

Roloc Disks or equivalent
Isopropyl Alcohol
Ford Approved Epoxy Based Primer
Related Damage Only Part Numbers
LJ8Z-5803100-A Base Windshield VIN Specific – Only if breaks during removal procedure.
LJ8Z-5803100-H High Series Windshield

 


CERTAIN 2021 MODEL YEAR MUSTANG MACH-E VEHICLES — WINDSHIELD AND PANORAMIC GLASS REATTACHMENT

 

SERVICE PROCEDURE – BODY SHOP INSTRUCTIONS

NOTE:  These instructions are not intended to be followed from beginning to end. There are several locations where procedures must be completed by other groups before the procedure in these instructions can be resumed.

The instructions should be followed in this order.

1. Body Shop Part One – Prepare vehicle for repairs – Steps 1-5

2. Glass Company Part One – Remove windshield – Steps 1-11 as required.

3. Body Shop Part Two – Improve Flange adhesion – Steps 6-13 as required.

4. Glass Company Part Two – Improve panoramic glass and install windshield – Steps 12-27

5. Body Shop Part Three – Calibrate Image Processing Module A – Steps 14-16

 

BODY SHOP – PART ONE

1. Remove the windshield wiper pivot arms. Please follow Workshop Manual (WSM) procedures in Section 501-16.

2. Remove the cowl panel grille. Please follow WSM procedures in Section 501-02.

3. Remove the headliner. Please follow WSM procedures in Section 501-05.

4. Remove the interior rear view mirror. Please follow WSM procedures in Section 501-09.

5. Disconnect the heated windshield electrical connector and tape the wires to the windshield to prevent damage. See Figure 1.

 

BODY SHOP – PART TWO

6. Cover/protect the body and interior of the vehicle with a one-time use, disposable drop plastic.

7. Using a scraper, cut the through the urethane bead vertically down to the painted surface to create a starting point. Once reaching the painted surface, pry one side of the bead up with the scraper. Using fingers, work to peel the urethane off the windshield body flange.

8. In areas where the urethane peeled up cleanly, use 400-600 grit sandpaper or a fine Scotch-Brite pad to manually scuff clear coat lightly until it displays a white haze being sure to only abrade the flange. See Figure 2.

 

9. In areas where the urethane did not peel up cleanly, use a Scotch-Brite 3M Roloc disk to remove all remaining urethane from flange while attempting to minimize abrasion to the painted surface. See Figure 3.

 

10. Clean off the entire windshield flange from all dirt and debris.

11. Using Isopropyl Alcohol and a lint-free cloth, clean off the flange surface. Allow one minute for the Isopropyl Alcohol to evaporate.

12. Apply tape to the edges of the windshield flange to protect the surface of the vehicle. See Figure 4.

 

13. Apply one coat of any Ford approved epoxy based repair primer to any spots where the roloc disk was used to grind off the urethane. Allow time for the primer to dry per the manufacturer’s instructions. See Figure 5.

 

BODY SHOP – PART THREE

NOTE:  Part Three may only be performed once the Glass Company repair procedures have been completed.

14. Remove the protective cover from the vehicle and clean off any dirt and debris.

15. Re-install all previously removed components by reversing steps 1-4.

16. After the windshield has been properly installed and the urethane has dried per the manufacturer’s         instructions, carry out the Image Processing Module A (IPMA) Camera alignment using a scan tool.

 


CERTAIN 2021 MODEL YEAR MUSTANG MACH-E VEHICLES — WINDSHIELD AND PANORAMIC GLASS REATTACHMENT

 

SERVICE PROCEDURE – GLASS COMPANY INSTRUCTIONS

NOTE:  These instructions are not intended to be followed from beginning to end. There are several locations where procedures must be completed by other groups before the procedure in these instructions can be resumed.

The instructions should be followed in this order.

1.   Body Shop Part One – Prepare vehicle for repairs – Steps 1-5

2.   Glass Company Part One – Remove windshield – Steps 1-11 as required.

3.   Body Shop Part Two – Improve flange adhesion – Steps 6-13 as required.

4.   Glass Company Part Two – Improve panoramic glass and install windshield – Steps 12-27

5.   Body Shop Part Three – Calibrate Image Processing Module A – Steps 14-16

 

GLASS COMPANY – PART ONE

1.  Apply tape to the perimeter of the windshield to protect from paint damage. See Figure 1.

NOTE: Tape off the roof panel near the centerline of the vehicle, where the roof extends forward. When using a piano wire to cut out the glass, the wire will roll over the class A paint in the roof area, once tension is applied to it. If using a nylon style string, this will not damage the paint.

 

2. Remove the windshield using a piano wire cut out tool. See Figure 2 where cutting fiber line was used.

3. Inspect the windshield for possible damage. Is there any damage to the windshield?

Yes – Replace the windshield. Proceed to Step 4.

No  – Re-install the original windshield. Proceed to Step 12.

NOTE: Damage to the alignment pins does not require windshield replacement.

4. Use glass cleaner to clean the surface of the new windshield to be installed.

5. Release the tabs and remove the in-vehicle temperature and humidity sensor. See Figure 3.

 

6. Re-install the temperature and humidity sensor into the new windshield.

7. Remove the Image Processing Module A (IPMA) Camera. See Figure 4.

1. Release the tab.

2. Release the tab and remove the IPMA camera.

8. Re-install the IPMA camera into the new windshield.

9. Remove the rain sensor. See Figure 5.

1. Release the retainers.

2. Remove the rain sensor.

 

10. Inspect the rain sensor gel pack for damage. See Figure 6.

NOTE: If the rain sensor gel pack is damaged, install a new rain sensor.

 

11. Re-install the rain sensor into the new windshield.

 

GLASS COMPANY – PART TWO

NOTE:  Part Two may only be performed once the Body Shop repair procedures to the window flange have been completed.

12. Shave down the urethane on the original windshield until there is 1mm remaining. See Figure 7.

 

13. Apply two coats of urethane body flange primer according to the manufacturer’s instructions to the entire windshield body flange at the urethane location. Additionally, apply two coats of window primer at any location where the clearcoat or paint layers have been damaged to provide environmental protection. Allow dry time between each coat applied.

Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207

14. Apply window primer according to the manufacturer’s instructions to the new windshield. Allow dry time.

Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207

NOTE: This step only applies when replacing the windshield.

15. Apply window primer according to the manufacturer’s instructions to the fixed glass anywhere the urethane adhesive was completely removed. Allow dry time.

Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207

NOTE: This step only applies when reusing the original windshield.

16. Using Isopropyl Alcohol and a clean lint-free cloth or moistened dobber, clean the flange in the area where the primer is to be applied along the front header flange of the panoramic roof. See Figure 8.

NOTE:  The tape is for locational reference only. It is not required to apply tape before cleaning the flange.

 

17. Repeat step 16 on both the rear bow and the side rails. See Figures 9 and 10.

 

18. Apply two coats of urethane body flange primer according to the manufacturer’s instructions using a dauber to the front header. Allow dry time between each coat applied. See Figure 11.

Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207

 

19. Repeat step 18 on both the rear and the side rails.

NOTE:  Please follow the website link https://bcove.video/3vaAI6C for applying the primer at the rear bow. Driver side shown, passenger side similar.

20. Using a 3M P.A.-1 hand applicator or similar tool, install one of the two extruded foam seal strips between the front header flange and the roof glass at a depth of 1/2″-1″ (12-25mm). See Figures 12 and 13.

NOTE:  The foam seal may extend past where the primer was applied. See Figure 14.

 

21. Using the second foam seal, cut two 5 inch long strips and install each strip between the rear bow and the roof glass. See Figures 15 and 16.

 

22. Cut the urethane adhesive applicator tip to specification. See Figure 17.

Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express Material: Sika Tack ASAP Urethane Adhesive

 

23. Apply a urethane adhesive bead. See Figure 18.

1. Start and end at the original overlap points to prevent air and water leaks.

2. Apply a urethane adhesive bead 14 mm (0.551 in) high and 8 mm (0.314 in) wide on top of the existing trimmed urethane adhesive bead on the pinch weld.

3. Make sure there are no gaps in the bead.

NOTICE: Make sure the urethane bead is uniform to prevent air and water leaks.

NOTE: The fixed glass must be installed within 10 minutes of applying the urethane adhesive.

NOTE: Use a power caulk gun that applies the urethane adhesive with less effort and a continuous bead.

 

24. Open the vehicle windows to prevent the air pressure of closing doors from compromising the urethane adhesive bond.

NOTICE: The door windows must be left open during the adhesive curing time.

25. Install the fixed glass to the vehicle.

1. Install the fixed glass, pressing firmly by hand to ensure a good bond.

2. Secure the fixed glass in the correct position with tape until the urethane adhesive has cured.

26. Apply urethane adhesive between the glass on both front and rear headers using the foam seal as a back stop to ensure the urethane wets out to both the flange and the glass. See Figures 19 and 20.

NOTE:  If tape was applied for locational reference, be sure to remove the tape directly after urethane application.

 

27. Repeat step 26  for the roof’s side rails using the urethane  as a back stop to acquire adhesive wet out to both the glass and the flange.

WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer’s curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
FORD MUSTANG MACH E 2021

 


12 Associated Documents

Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 21S42 Certain 2021 Model Year Mustang Mach-E Vehicles Panoramic Roof Glass Reseal

RCMN-21V712-5316.pdf 6957.347KB

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Recall 573 Report

RCLRPT-21V712-9665.PDF 214.297KB

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Recall 573 Report

RCLRPT-21V712-9398.PDF 214.314KB

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Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice Safety Recall 21S42 Certain 2021 Model Year Mustang Mach-E Vehicles Panoramic Roof Glass Reseal

RCMN-21V712-4494.pdf 133.563KB

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Recall 573 Report

RCLRPT-21V712-2479.PDF 215.479KB

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ISSUED Renotification Notice

RCRN-21V712-1907.pdf 82.237KB

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V712-2132.PDF 211.143KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V712-8877.pdf 52.958KB

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Recall Acknowledgement

RCAK-21V712-3941.pdf 645.454KB

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Defect Notice 573 Report

RCLRPT-21V712-7184.PDF 214.158KB

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Recall Quarterly Report #2, 2022-1

RCLQRT-21V712-2342.PDF 211.256KB

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ISSUED Renotification Notice

RCRN-21V712-3615.pdf 488.973KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V712&docType=RCL

 


 

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