Power Windows: Removal & Installation Ford Thunderbird X

REMOVAL & INSTALLATION

Removal

1. Remove door trim panel and watershield. See «DOOR TRIM»(ref-138006-S41327330892002050700000).
2. Position glass to full-up position.
3. Remove two electrical wire clips from retainer assembly.
4. Remove screws and washer assembly securing retainer assembly to inner door panel. see scheme 5
5. Remove retainer assembly by applying a downward pressure to disengage top end from slip on joint.

Installation

1. Install retainer assembly by first aligning upper end to door frame bracket at door belt so that upward pressure applied to retainer assembly will cause it to slip onto joint.
2. Align lower bracket of retainer assembly to door inner panel and install screw and washer assembly. Tighten screw and washer assembly to 7-14 N. m (6-10 Ft. Lbs.).
3. Install two electrical wire clips.
4. Cycle glass to check for proper operation.
5. Install door trim panel and watershield. See «DOOR TRIM»(ref-138006-S41327330892002050700000) .

1. Remove door trim panel and watershield. See «DOOR TRIM»(ref-138006-S41327330892002050700000).
2. Remove inside door belt weatherstrip assembly. see scheme 5
3. Lower glass to access holes in door inner panel. Remove two nuts retaining glass to glass bracket.
4. Loosen nut and washer retaining door glass stabilizer.
5. Remove glass by tipping it forward then removing from between door belt opening to outboard side of door.

1. Install glass into door at belt. Ensure that glass is set within front and rear glass run retainers.
2. Position glass to glass bracket. Install two nuts to secure glass to glass bracket. Tighten nut and washer assemblies to 7-14 N. m (6-10 Ft. Lbs.).
3. Install inside door belt weatherstrip assembly.
4. Raise glass to within 75mm (3 inches) of full-up position and adjust glass as outlined.
5. Install door trim panel and watershield. See «DOOR TRIM»(ref-138006-S41327330892002050700000) .

1. Remove window regulator switch housing.
2. Remove door inside handle cup (snaps out). (Scheme 1)
3. Remove self-tapping screw retaining door trim panel upper front extension assembly. Remove extension assembly.
4. Remove two self-tapping screws retaining door trim panel to door inner panel.
5. Lift door trim panel upward and snap out trim panel.
6. Disconnect wire harness for courtesy lamp.

1. Connect courtesy lamp connector.
2. Install door trim panel (lower portion first). Push in until it snaps in place.
3. Install two self-tapping screws retaining trim panel to inner panel.
4. Position extension assembly. Install self-tapping screw.
5. Snap in door inside handle cup.
6. Install window regulator switch housing.

Scheme 1

1. Inside sail cover. Inside and outside door belt weatherstrips. Front glass run retainer attaching screw. see scheme 5 Front door glass. See «DOOR GLASS»(ref-138006-S39034173282002040100000). Outside rear view mirror. See appropriate POWER MIRRORS article.
2. To remove glass run assembly, carefully pull run assembly off window opening pinch weld and remove through window opening.

Note. This procedure requires two people, one inserting the front leg and another person holding the remainder of glass run at center section to prevent bending. After the front (A-pillar section) and the rear (B-pillar section) of the glass run assembly is inserted into the door.

Note. Apply lubricant ESB-M99C109-A to glass run assembly from point Y to point Z. See LUBRICATION under ON-VEHICLE SERVICE.

1. Locate moulded B-pillar corner of glass run from pinch weld flange to upper corner of door frame.
2. Apply hand pressure to glass run from belt line area of B-pillar and push run upward (vertically) into corner. Ensure run is fully flush with sheet metal.
3. While applying upward pressure along B-pillar, install run onto door frame pinch weld along B-pillar starting from top and moving downward. Use hand pressure to ensure glass run is flush with outer door panel sheet metal.
4. Use hand pressure from center to upper door frame area, and push glass run rearward along pinch weld flange into B-pillar upper corner. Ensure glass run is flush with outer door panel sheet metal at corner.
5. While applying hand pressure rearward, install glass run onto door frame pinch weld along upper door frame starting from B-pillar and point to A-pillar.
6. Use hand pressure from lower A-pillar leg of glass run and push run upward (vertically) into corner. Ensure run is fully flush with outside sheet metal.
7. While applying upward hand pressure along A-pillar, install glass run onto door frame pinch weld. Use hand pressure to fully seat run. Ensure glass run leg is fully seated.
8. Install front retainer to door inner panel with screw and washer assembly. Tighten to 7-14 N. m (6-10 Ft. Lbs.).

1. Remove circuit breaker from its cavity. see scheme 3
2. Replace the blown circuit breaker with the same approved amp rating for that particular circuit. To install the new circuit breaker, push straight in until the circuit breaker seats itself fully in the cavity.

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.
3. Remove door trim panel and watershield. See «DOOR TRIM»(ref-138006-S41327330892002050700000).
4. Disconnect window motor connector. see scheme 5
5. Position the motor wiring harness out of the way. Using a 19mm (3/4 inch) hole saw with a 1/4-inch pilot, drill three holes at the existing drill dimples located on the door inner panel adjacent to the motor.
6. Remove the three window motor retaining screws and disengage the motor and drive assembly from the regulator quadrant gear.

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 retaining screws to 5.6-9.6 N. m (50-84 INCH Lbs.).
3. Install the door trim panel and watershield. See «DOOR TRIM»(ref-138006-S41327330892002050700000) .
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.

Removal (Switch)

1. Remove screw retaining switch housing assembly. Rotate housing up and out of armrest to remove. (Scheme 2)
2. Remove two connector retaining screws from bottom of 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 2

Installation (Switch)

1. To install, position switch to the connector and press firmly into place.
2. Install switch housing and retaining screw.
3. Install connector to switch housing using two retaining screws.

Removal & Installation (Connector Wire)

If replacement of the switch connector or a wire leading to the connector is necessary, the wire(s) can be removed from the connector without disassembling the connector. To remove a wire from the connector, insert a needle-like tool in the edge of the terminal hole, and bend the terminal in. Pull the wire and terminal from the connector. (Scheme 3) To install the terminal in the connector, open the terminal and insert it into the wire hole.

Scheme 3

1. Remove door trim panel and watershield. See «DOOR TRIM»(ref-138006-S41327330892002050700000).
2. Lower glass to access holes in door inner panel. Remove two nut and washer assemblies retaining glass to glass bracket. see scheme 5
3. Prop the glass in the full-up position.
4. Disconnect the electric motor wiring.
5. Remove two nut and washer assemblies retaining regulator equalizer bracket.
6. Remove the center pin from each rivet with a drift punch. Using a 6mm drill, drill out the remaining of the rivet using care not to enlarge the sheet metal retaining holes.
7. Remove regulator through door access hole.

1. With glass in full-up position, install window regulator through access hole in door inner panel.
2. Position regulator base plate to door inner panel and install four rivets.
3. Install regulator equalizer bracket to regulator and loose assemble with two nut and washer assemblies.
4. Install regulator glass bracket drive channel to glass and secure with two nut and washer assemblies. Tighten nut and washer assemblies to 9-14 N-m (7-10 lb-ft).
5. Connect electric motor wiring.
6. Lower door glass approximately 75mm (3 inches) from full up position.
7. With door open, place hands on each side of glass and pull glass fully into door glass run assembly at B-pillar.
8. Apply a downward pressure on the equalizer bracket and tighten two nuts and washer assemblies. Tighten to 9-14 N. m (7-10 Ft. Lbs.).
9. Cycle door glass to ensure proper operation.
10. Install door trim panel and watershield. See «DOOR TRIM»(ref-138006-S41327330892002050700000) .