Power Windows Ford Explorer I

DESCRIPTION

The power window system consists of a regulator, motor and switch. The power window switch sends a signal to the power window module which in turn sends a voltage signal to the motor to move the window up or down. (Scheme 9), (Scheme 11), (Scheme 12) or (Scheme 13).

One-Touch Driver's Side Window (Explorer)

1. With the ignition switch in the accessory position, depress (tap) the driver's side window switch in the down position for less than 0.4 seconds. The window will continue downward until the window is fully lowered. If the window stops beforehand then possible binding within the window mechanism could exist.
2. Raise the window to its full up position.
3. Depress (tap) the driver's side window switch in the down position. Momentarily depress the switch again in either the up or down position. The window should stop the automatic down feature.
4. Raise the window to its full up position.
5. Depress the driver's side window for more than 0.5 seconds. The window will move downward until the switch is released.

Driver's Side Window (Ranger)

Pushing up on the power window switch moves the window up. Pushing the power window switch down moves the window down. (Scheme 8), (Scheme 19) or (Scheme 10).

COMPONENT LOCATIONS

COMPONENT LOCATIONS

LUBRICATION

The door window mechanism should be properly lubricated to provide ease of operation. The window glass mechanism should be lubricated whenever the glass channel or window regulators are removed or excessive effort is required to operate the windows. To lubricate a door window mechanism, apply an even coating of Premium Long-Life Grease XG-1-C or -K (ESA-M1C75-B) or equivalent to the window regulator rollers, shafts and the entire length of the roller guides as illustrated by the shaded areas. (Scheme 1)

Scheme 1

FRONT WINDOW MECHANISM (EXPLORER & RANGER)

1. Remove door trim panel and watershield. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) in REMOVAL & INSTALLATION.
2. Lower glass approximately 2-3 inches (51-76 mm) from full UP position.
3. Loosen three guide assembly nut and washer assemblies.
4. Push glass rearward, within the door glass run assembly, until it bottoms out within the door frame.
5. Move window guide post rearward within retention slot in inner panel. Tighten three guide assembly nut and washer assemblies. See «TORQUE SPECIFICATIONS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows__torque-specifications) .
6. Cycle glass up and down to check position.
7. Install watershield and trim panel. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) in REMOVAL & INSTALLATION.

REAR WINDOW MECHANISM (EXPLORER)

1. Remove door trim panel and watershield. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) in REMOVAL & INSTALLATION.
2. Loosen, but do not remove, upper regulator attachment nuts.
3. Raise the glass to full up position and tighten nuts. See «TORQUE SPECIFICATIONS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows__torque-specifications) .
4. Loosen, but do not remove, front glass retainer bolt.
5. Lower glass to full down position and tighten retainer bolt. See «TORQUE SPECIFICATIONS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows__torque-specifications) .

Note. On Explorer with rear door cable-drive window regulator cable, when servicing the door glass system, window regulator or window regulator drive assembly (motor), the tension on the window regulator cable must not be altered. The proper cable tension has been pre-set at the production plant to insure correct function of the window regulator through the total life of the unit. Improper cable adjustment may result in premature window regulator failure or erratic window operation.

WINDOW MECHANISM (AEROSTAR)

There are no adjustments on Aerostar.

DRIVER'S MASTER SWITCH (EXPLORER 4-DOOR ONLY)

1. Use a self-powered test lamp or Rotunda Digital Volt-Ohmmeter (007-00001) or equivalent to test the power window switch.
2. With the switch in the NEUTRAL position, there should be continuity between terminals No. 1, 2, 3, 4, 5, 6, 7, 8 and 9 and terminals No. 10 and 11. (Scheme 2) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
3. When the raised portion of all the switch rocker knobs is pushed (to raise the windows), there should be continuity between terminals No. 1, 3, 5, 7, 10 and 11 and terminals No. 2, 4, 6, 8 and 9. (Scheme 2) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
4. When the depressed portion of all the switch rocker knobs is pushed (to lower the windows), there should be continuity between terminals No. 1, 3, 5, 7 and 9 and terminals No. 2, 4, 6, 8, 10 and 11. (Scheme 2) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
5. With the lockout switch button depressed into its detented position, terminal No. 11 should not have continuity with any other terminal. (Scheme 2) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
6. If the switch does not test as stated, replace the switch.

Scheme 2

ONE-TOUCH DRIVER'S SIDE WINDOW SWITCH (EXPLORER)

1. Use a 12-volt test lamp or Rotunda Digital Volt-Ohmmeter (007-00001) or equivalent to test the one-touch control module.
2. With the ignition switch in the accessory position, connect a test lamp between terminal 5 (ground), Circuit 57 and terminal 3 (power), Circuit 400. The lamp should light. (Scheme 3) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
3. With the test lamp connected to terminal 3 (power), Circuit 400, connect the other end of the test light to. (Scheme 3) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows). Terminal No. 1 (motor), Circuit 903. The lamp should light. Terminal 2 (driver's power window switch down), Circuit 226. The lamp should light. Terminal No. 4 (driver's power window switch up), Circuit 227. The lamp should light.
4. Use a self-powered test lamp or ohmmeter to test the one-touch control module.
5. With the one touch control module removed from the vehicle, check continuity between terminals No. 1 and 2. The lamp should light. (Scheme 3) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
6. Check continuity between terminals No. 1 and 3. The lamp should not light.

Scheme 3

Single Switch

1. Use a self-powered test lamp or an ohmmeter to test the power window switch.
2. With the switch in the neutral position, there should be continuity between terminals No. 1 and 3, 2 and 5, and 4 and 6. (Scheme 4) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
3. With the toggle switch pushed downward, there should be continuity between terminals No. 2, 4 and 5, and 1 and 3. Terminal No. 6 should be disconnected from any other terminal.. (Scheme 4) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
4. With the toggle switch pushed upward, there should be continuity between terminals No. 2, 3 and 5, and 4 and 6. Terminal No. 1 should be disconnected from any other terminal.. (Scheme 4) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
5. If the switch does not test as stated, replace the switch.

Scheme 4

Multiple Switch

Note. Testing of the power window multiple switch should be performed with the switch removed from the vehicle. Refer to the appropriate procedures in this section. Use a self-powered test lamp or an ohmmeter such as Rotunda Digital Volt-Ohmmeter (007-00001), or equivalent.

1. Clip one test lead probe on pin Terminals No. 6 which is grounded. (Scheme 5) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
2. With both switches in the neutral position, terminals No. 1 through 4 should have continuity to terminal No. 6. (Scheme 5) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
3. Push both window switches upward (toward window when in installed position). Both terminals No. 1 and 3 should have no continuity to terminal No. 6. (Scheme 5) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
4. Push both window switches downward (away from window when in installed position). Both terminals No. 2 and 4 should have no continuity to terminal No. 6. (Scheme 5) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
5. Remove the test lead from terminal No. 6 and connect to terminal No. 5 (hot feed pin). With both switches in the neutral position, terminal No. 5 should have continuity only with itself. (Scheme 5) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
6. Push both window switches upward (toward the window when in installed position). Both terminals No. 1 and 3 should have continuity to terminal No. 5. (Scheme 5) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
7. Push both window switches downward (away from the window when in installed position). Both terminals No. 2 and 4 should have continuity to terminal No. 5. (Scheme 5) See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
8. If any one switch does not test as stated, replace the complete switch assembly.

Scheme 5

POWER WINDOW SWITCH (EXPLORER & RANGER)

Note. The switch should be oriented so that the raised portion of the switch knob is to the right and you are looking at five terminals. (Scheme 6)

1. Use a self-powered test lamp or Rotunda Digital Volt-Ohmmeter (007-00001) or equivalent to test the power window switch.
2. With the switch in the NEUTRAL position there should be continuity between terminals No. 1 and 2 and terminals No. 3 and 4. Terminal No. 5 should be disconnected from all other terminals. (Scheme 6)and (Scheme 7). See «WIRING DIAGRAMS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
3. When the raised portion of the switch rocker knob is pushed (to raise the window), there should be continuity between terminals No. 1 and 5 and terminals No. 3 and 4. Terminal 2 should be disconnected from all other terminals. (Scheme 6)or (Scheme 7).
4. When the depressed portion of the switch rocker knob is pushed (to lower the window), there should be continuity between terminals No. 1 and 2 and terminals No. 4 and 5. Terminal 3 should be disconnected from all other terminals. (Scheme 6)or (Scheme 7) and (Scheme 21) or (Scheme 22).
5. If the switch assembly does not test as stated, replace the switch.

Scheme 6

Scheme 7

POWER WINDOW MOTOR

Note. To test the current draw of a power window motor, remove the door trim panel. See DOOR TRIM PANEL in REMOVAL & INSTALLATION.

1. Disconnect the motor lead.
2. Disconnect the regulator mechanism from the motor.
3. Supply power to motor lead connector with an ammeter in series.
4. Operate the motor and observe the current draw. The current draw for the no-load test should not exceed four amps and should not fluctuate. Reversal of the motor wire connections will reverse the direction of motor rotation. Replace the motor if the current draw exceeds four amps.

REMOVAL & INSTALLATION

Removal

1. Remove the screws retaining the armrest area of the trim panel to the door inner panel.
2. Remove the screw retaining the door inside handle cup.
3. Remove the screw retaining the door window regulator handle. Remove the handle and washer.
4. Remove the power door lock control and/or power window control, if so equipped.
5. At each plastic clip location, carefully pry the trim panel away from the door inner panel using the Trim Pad Removing Tool from Rotunda Moulding/Trim Kit 107-00401 or equivalent. Remove the trim panel. NOTE: At no time should the trim panel be used to pull the clips from the inner panel holes.

Scheme 8

Installation

1. Replace any bent, damaged, or missing push pins on the door trim panel. Position the trim panel to the door inner panel, locating the push pins in the countersunk holes. Firmly push the trim panel at the push pin locations to seat each push pin into the holes in the door inner panel.
2. To complete installation, reverse removal procedure.

1. Remove the door trim panel and watershield. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .
2. If vehicle is equipped with power windows, disconnect the wire from the regulator.
3. Remove the door glass.
4. Remove the window guide, if equipped, (three nuts and washers) and remove guide from door belt opening.
5. Remove the glass bracket assembly, if equipped, from the door, sliding the bracket C-channel off the regulator arm side/roller.
6. Remove the center pin from the regulator attaching rivets with drift punch. Then, drill out remainder of rivet heads using a 1/4-inch (6.35 mm) drill. Be careful not to damage sheet metal holes during drilling.
7. Remove regulator from the door.

Scheme 9

Scheme 10

Scheme 11

1. Position door window regulator in door and align retention holes to door inner panel.
2. Install four rivets attaching regulator to door inner panel using Rotunda Blind Fastener Installation Tool (107-00600) or equivalent. NOTE: A 1/4 20 x 1/2-inch screw and washer assembly and a 1/4 20 nut and washer assembly may be used for retention if 1/4-inch rivets are not available (equivalent metric retainers may also be used).
3. Assemble glass bracket to regulator arm slide.
4. Insert center guide through door access hole, sliding C-channel onto glass bracket slides and three retaining studs through door inner panel.
5. Install three nut and washer assemblies to window guide retention studs; do not tighten at this time.
6. Install door glass.
7. Adjust door glass. See «ADJUSTMENTS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) . Tighten the three nut and washer assemblies-to-window guide retention studs. See «TORQUE SPECIFICATIONS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows__torque-specifications) .
8. Reconnect wire to regulator for power window if equipped.
9. Check operation of window regulator.
10. Install door watershield and trim panel. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .

1. Raise the window to the full-up position, if possible. If the glass cannot be raised and is in a partially down position, it must be supported so that it will not fall into the door well during motor removal.
2. Disconnect battery ground cable. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
3. Remove door trim panel and watershield. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .
4. Disconnect window motor connector.
5. Position the motor wiring harness out of the way. There are two holes and one drill dimple located on the door inner panel adjacent to the motor.
6. Remove the three window motor mounting screws and disengage the motor and drive assembly from the regulator quadrant gear.

Scheme 12

Scheme 13

1. Position the motor and drive to the regulator and install the three screws snug, not tight.
2. Connect the motor wires at the connector and cycle the glass to ensure gear engagement. After the gears are engaged, tighten the three motor and drive attaching screws. See «TORQUE SPECIFICATIONS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows__torque-specifications) .
3. Install watershield and trim panel. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) . NOTE: Appropriate plug buttons may be installed to cover the exposed hole at the trim panel edge, if necessary.
4. Connect battery ground cable.
5. Check the drain holes at the bottom of the doors to ensure that each is open to prevent water buildup over the motor.

1. Remove the door trim panel and watershield. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
2. Remove inside door belt weatherstrip and glass stabilizer.
3. Remove door glass.
4. Remove two nut and washer assemblies attaching the equalizer bracket.
5. Remove three rivets (manual) or four rivets (power) attaching the regulator base plate to door inner panel.
6. Remove regulator and glass bracket assembly from vehicle.
7. Working on a bench, carefully bend tab flat to remove arm slides from glass bracket C-channel.
8. Install new regulator arm plastic guides into glass bracket C-channel and bend tab back to 90 degrees. (Use care not to break tab; if tab is cracked or broken, replace glass bracket assembly. Make sure rubber bumper is installed properly on new glass bracket, if replacement is made). (Scheme 14)

1. Install regulator with preassembled glass bracket into vehicle. Set the regulator base plate to door inner panel using base plate locator tab as a guide.
2. Install four rivets to attach regulator to door inner panel.
3. Install equalizer bracket.
4. Install inside door belt weatherstrip and glass stabilizer.
5. Lower regulator arms to access holes in door inner panel. Install door glass.
6. Adjust glass to ensure proper alignment with glass run. See «ADJUSTMENTS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) . Cycle glass for smooth operation.
7. Install door watershield and trim panel. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .

Scheme 14

POWER WINDOW MOTOR (AEROSTAR)

1. Disconnect the battery ground cable. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
2. Remove the door trim panel. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).
3. Disconnect power window motor wire harness connector. (Scheme 15)
4. Check inside the door to make sure electrical wires are not in line with holes to be drilled in the door inner panel. Using a 12.7mm (1/2-inch) diameter drill bit, drill two holes in the door inner panel at the drill dimples located opposite the two unexposed motor drive retainer screws. (Scheme 16)
5. Remove the three motor mount retainer screws using two drilled holes and existing larger hole access to screw heads.
6. Push the motor toward the outside sheet metal to disengage the motor and drive from the regulator gear. After the motor and drive are disengaged, prop the window in full up position.
7. Remove the motor and drive from inside the door.

1. Install a new motor and assembly. Tighten motor retaining screws. See «TORQUE SPECIFICATIONS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows__torque-specifications) .
2. Install two pieces for Pressure Sensitive Waterproof Tape D6AZ-19627-A or equivalent body tape 25.4mm (1 inch) square over drilled holes.
3. Connect power window motor wiring, and battery ground cable.
4. Remove glass prop and check window operation.
5. Make sure door drain holes are open.
6. Install trim panel. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .

Scheme 15

Scheme 16

Note. When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

1. Disconnect battery ground cable.
2. Remove door trim panel and watershield. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .
3. Disconnect power window motor wire from wire harness connector.
4. Remove motor and regulator assembly.
5. Remove motor and drive from regulator (three retaining screws).

1. Install new motor and drive assembly to regulator. Tighten motor retaining screws. See «TORQUE SPECIFICATIONS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows__torque-specifications).
2. Install motor and regulator assembly in door. (Scheme 17)
3. Connect power window motor wiring, and battery ground cable.
4. Check window operation.
5. Make sure door drain holes are open.
6. Install watershield and trim panel. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows).

Scheme 17

1. The power window switches are located on the front door trim panels. To replace a switch, remove the bezel by carefully prying the bezel up with a flat-bladed tool. (Scheme 18)
2. Remove the wiring connector retaining nuts from the back of the bezel. Using a thin-bladed screwdriver, carefully pry the switch from the connector. (Scheme 18)
3. To install the switch, reverse the above procedure.

Scheme 18

Note. The power window switches are located on the front door trim panels (Ranger). The power window switches are located on the front door armrests (Explorer).

1. On Ranger, insert a small, thin-bladed screwdriver into the spring tab slots (located at the front and rear of the switch housing) and apply pressure to make the switch housing pop out. On Explorer, using a thin-bladed tool, carefully pry up the rear of the switch housing and rotate the housing up and out of the armrest.
2. On Ranger, remove the three or on Explorer four connector attaching screws from the switch housing.
3. The switch is held in place by the electrical contact pins. To remove the switch, carefully pry the switch from the connector with a small screwdriver.

Scheme 19

1. Position the switch to the connector and press firmly into place. NOTE: The switch is keyed to the connector and can only be installed one way. (Scheme 20)
2. Install the connector to the switch housing using, the three on Ranger or four on Explorer, attaching screws. (Scheme 20)
3. On Ranger, position the switch housing to the door trim panel and press firmly into place. On Explorer, install the switch housing to the armrest by hooking the front of the housing to the armrest and pushing the rear of the housing firmly into place. (Scheme 20)

Scheme 20

1. Disconnect battery ground cable.
2. Remove door trim panel and watershield. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .
3. Disconnect power window motor wire from wire harness connector.
4. Remove three 1/4-inch rivets attaching the motor bracket to inner panel. Use drift pin to knock out the center pins from each rivet. Using a 1/4-inch diameter drill, drill out the remainder of the rivet. Use care not to enlarge sheet metal holes in the door inner panel.
5. Working through access holes, remove motor attaching screws and separate motor from bracket and cable drum housing.
6. Remove motor from inside door.

1. Position the motor and drive to cable drum housing and motor mounting bracket and install three motor screws. Tighten screws. See «TORQUE SPECIFICATIONS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows__torque-specifications)
2. Connect power window motor wiring and battery ground cable.
3. Check window operation. Install watershield, door trim panel, and armrest. «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows)

1. Remove the door trim panel and watershield . See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .
2. If vehicle is equipped with power windows, disconnect the wire from the regulator.
3. Remove the door glass.
4. Remove the window guide, if equipped, (nuts and washers) and remove guide from door belt opening.
5. Remove three 1/4-inch rivets attaching motor bracket (electric) to inner panel and two 1/4-inch rivets attaching lower bracket of regulator to inner panel. Use drift punch to knock out center pins for each rivet. Using a 1/4-inch diameter drill, drill out the remainder of the rivet. Use care not to enlarge sheet metal holes in the door inner panel.
6. Remove two upper regulator attaching nuts.
7. Remove regulator from the door.

1. Lubricate regulator mechanism with Multi-Purpose Grease D0AZ-19584-AA or equivalent.
2. Install regulator into access hole in inner panel.
3. Position regulator using upper regulator studs and tabs on motor mounting bracket.
4. Install rivets attaching regulator to door inner panel (1/4-20 x 1/2 inch bolt and 1/4-20 nut and washer assemblies or equivalent metric fasteners may be used as alternates).
5. Install two upper regulator attachment nuts.
6. Install door glass.
7. Adjust glass. See «ADJUSTMENTS»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .
8. Reconnect wire to regulator.
9. Check operation of window regulator.
10. Install door watershield and trim panel. See «DOOR TRIM PANEL»(/ford/explorer/i-1990-1994/remont/windows/#power-windows) .

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 21

System Wiring Diagram (Explorer 2-Door). Scheme 22

System Wiring Diagram (Explorer 4-Door). Scheme 23

System Wiring Diagram (Ranger). Scheme 24

See also:
• DOOR TRIM PANEL
• TORQUE SPECIFICATIONS