and gain access to Reviews and Discussion of the 2016 and 2017 Ford Explorer Tech Tips, How to Articles, Off-Road Modifications and Events, Street Truck Mods and Events, and much more! Since 1996 our community has covered every aspect of the Ford Explorer, Ford Ranger and all vehicles based on this platform.

Register Today It's free! This box will disappear once registered!

96 Ex Power Window Bushing Fix with Pics!

Discussion in 'Stock 1995 - 2001 Explorers' started by lunchboxx, July 24, 2008.

  • Searches ExplorerForum.com
    1. lunchboxx

      lunchboxx New Member

      Joined:
      February 21, 2008
      Messages:
      26
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Roanoke, VA
      Year and Model:
      2000 pontiac bonneville
      As I have posted before..I dont even own an explorer, But I married in to one!:rolleyes:

      So I have one to work on now. This forum is one of my new best friends.
      Well, my sister in law went to Italy for a freakin week and her Explorer came to my driveway to visit, so I figured I would poke around.

      Here is the window fix: I apologize in advance for not noting the nut and bolt sizes, but I figure if you are going to take on this project, you have a set of tools and are dangerous enough to think you can use them....

      This would be the time to disconnect the battery if you were a "Safety Sam" kinda guy..I however, enjoy the feeling of 12V in my body..so I didnt.


      Approach the door..ask it to dance
      [​IMG]

      Remove these two screws. And then use a flat blade screwdriver to Jimmy off the inner door handle trim cover
      [​IMG]
      GENTLY start to pull the door off or use the special plastic insert remover tool.

      Unhook this trim light. it twists and then comes out IIRC
      [​IMG]

      This is the back of the lock/unlock and window up/down button switch. The whole thing just pushes in towards the door.You dont even have to unhook it
      [​IMG]

      Start a pile on your well manicured lawn
      [​IMG]
       
    2. Support EF


      Join the Elite Explorers for $20 a year

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose and fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, add your own profile photo, upload photo attachments directly to your posts and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.



      to hide adverts.
    3. lunchboxx

      lunchboxx New Member

      Joined:
      February 21, 2008
      Messages:
      26
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Roanoke, VA
      Year and Model:
      2000 pontiac bonneville
      Slowly peel off this plastic. Try not to rip it, it needs to be there or Ford engineers would not have put it in there, right?
      [​IMG]

      Removing this green Ground screw will allow the wiring harness to dangle and give you some more room to move and work
      [​IMG]

      Remove the 3 speaker retaining screws
      [​IMG]

      Detach speaker clip w/ screwdriver
      [​IMG]
       
    4. lunchboxx

      lunchboxx New Member

      Joined:
      February 21, 2008
      Messages:
      26
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Roanoke, VA
      Year and Model:
      2000 pontiac bonneville
      You need to drill a 1/2 inch hole RIGHT HERE
      [​IMG]

      It will end up looking like this
      [​IMG]

      Pull the three motor bolts out and take it somewhere to work on it. My wife loves me, so I get the kitchen table :) Remove the TORX bolt (T20 i think)
      [​IMG]

      Pop off the top w/ a screwdriver
      [​IMG]

      Using a set of needle nose, push back on both sides of the retaining clip at the same time and shoot it across the kitchen. CUSS, ALOT. Find the clip and take a picture of it
      [​IMG]
      Remove metal and plastic gears..Notice a significant LACK of bushings..and a funny smell...
      [​IMG]
       
    5. lunchboxx

      lunchboxx New Member

      Joined:
      February 21, 2008
      Messages:
      26
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Roanoke, VA
      Year and Model:
      2000 pontiac bonneville
      BUY some of these
      [​IMG]

      If you are comfy with the guts of an electric motor, and are feeling Ballsy..do what I did and take the armature out and look at all the little bits of old bushing that would never have been cleaned if you didnt take it apart. But, if you get it back together and then the motor wont work..dont blame me..I warned ya!
      [​IMG]
      [​IMG]

      Clean the little bits of bushing out of everything with a jewlers screwdriver if you have one..
      [​IMG]

      Then assembly is reverse of removal..I greased everything up pretty good with grease. You may have to put the motor where it goes and start the screws, then run the motor in short bursts while pushing toward yourself with your arm inside the door cavity until the motor teeth pop into the regulator teeth. Then just button her back up.

      Difficulty rating: 6 beers
       
    6. CDW6212R

      CDW6212R Elite Explorer

      Joined:
      June 17, 2004
      Messages:
      14,337
      Media:
      3
      Albums:
      1
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Knoxville, TN
      Year and Model:
      98 Mountaineer AWD
      Very good work. Now... what, no blood? That's good work to finish with no busted knuckles.
       
    7. lunchboxx

      lunchboxx New Member

      Joined:
      February 21, 2008
      Messages:
      26
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Roanoke, VA
      Year and Model:
      2000 pontiac bonneville
      Oh there was blood..just no knuckles..LOL
       
    8. CDW6212R

      CDW6212R Elite Explorer

      Joined:
      June 17, 2004
      Messages:
      14,337
      Media:
      3
      Albums:
      1
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Knoxville, TN
      Year and Model:
      98 Mountaineer AWD
      Well still, you have all of your fingers, the window regulators are very dangerous if loosened. You only worked on the motors, which is the safest job.
       
    9. lunchboxx

      lunchboxx New Member

      Joined:
      February 21, 2008
      Messages:
      26
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Roanoke, VA
      Year and Model:
      2000 pontiac bonneville
      Truly they are big ugly Spring loaded finger removing machines!
       
    10. geoclint

      geoclint New Member

      Joined:
      September 19, 2008
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      Year and Model:
      '96 XLT
      Thanks for the great instructions and pictures. The only addition I would add is to drill the hole a little larger than 1/2" since the bolt was not perfectly centered with the dimple. By the way, no blood, no sweat, no missing fingers thanks to your warnings.
       
    11. lunchboxx

      lunchboxx New Member

      Joined:
      February 21, 2008
      Messages:
      26
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Roanoke, VA
      Year and Model:
      2000 pontiac bonneville
      Glad that I could be of help. It seems silly for everyone to go at it blind after one of us has done it already.
       
    12. Sams01XplrSprt

      Sams01XplrSprt Southern Cali Explorer Elite Explorer

      Joined:
      November 14, 2004
      Messages:
      15,667
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Newport Beach California & Bay Area California
      Year and Model:
      2001 Sport (sold)
      very good work
       
    13. luvmyexpl

      luvmyexpl New Member

      Joined:
      July 12, 2009
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Loxahachee,fl
      Year and Model:
      1996
      Life Saver. Nice Work!

      LunchBox, all i can say it thanks for the great pictures and directions. I bought the 96 Explorer I have now for my 16 year old daughter. When I got it the Windows did not work. I just pumped $700 into it for brakes, tires, checkup. I also painted all the Trim that was faded. You know all that Black trim that always fades on the Explorers?

      Well I could not afford to have them do the Windows also so i followed your directions. I even found the same exact gear plugs from Bennet Auto Supply. They have them behind the counter. I printed out the picture you took and they found them immediately. These help parts are at most Auto Parts stores. They cost me $7 for two pairs. I also bought some grease to re apply. I saw someone mentioned they had to shave the bushings to get them to fit. These bushngs are rubber and do move. I slided them in and used the back of a flat head screwdriver to snug them in.

      You will even like this. When I took the motor out I showed my wife where you wrote that the work had to be done on the kitchen table. Thats where i did it! Also thanks to your posting I was careful when taking the clip off so it would not fly through the kitchen! I did scre one thing up though. When I took the panel off I busted the vanity bulb on the bottom and it shorted and blew the fuse that controls the interior lights and also happens to control the Power Windows.The windows were not working after I tested them and they did work. I replaced the fuse in the interior panel and good to go.This was relatively easy and dare I say a fun project for me. It was gratifying knowing that I could fix both windows for less than $10!

      Thank you Lunchbox.:thumbsup:
       
    14. covshark

      covshark New Member

      Joined:
      July 29, 2009
      Messages:
      5
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Ocala, Florida
      Year and Model:
      96 xlt 4.0 OHV
      great write up. My power window was making a clicking noise whever the window button was pressed, sure enough all 3 of those window regulator gear plugs were chopped into tiny lil bits.

      Great thread with great pictures and info. Thanks :thumbsup: This needs a Sticky
       
      Last edited: August 2, 2009
    15. Yerba1

      Yerba1 New Member

      Joined:
      December 19, 2007
      Messages:
      18
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Wasatch Front Utah - Love the Canyons of Sanpete County
      Year and Model:
      1993 Clean one owner
      great job! thanks a million!

      Without this post - I would have never found that third screw. I was about 5 minutes from drilling out the rivets - when I decided to check here! I had the motor out in 10 minutes - clip off - I had to "bend" the cover up because the fourth screw was a rivet. The plastic beads cost me 8 dollars at Autozone - the plastic mounting pins were garbage so I'll get some universal pins tomorrow and secure the door completely. I can't believe that the three plastic beads were all that I needed. I'll bet more than one customer has paid for a new regulator + shop time for an $8.00 fix. My '91 is ready to be passed to my next sixteen year old. My fourteen year old is already hinting that she wants it next...:)
       
    16. 96_sport_ct

      96_sport_ct New Member

      Joined:
      August 2, 2010
      Messages:
      46
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Florida
      Year and Model:
      96 Sport control trac 4wd
      THANK YOU THANK YOU THANK YOU. i thought that my window motor was shot on the passenger side because it wouldnt make any sound at all when i hit the button. i could never find the last bolt till i read this. my gear plugs are shaped like beans. you just saved me tons of money and tons of time. i would imagine most people that have problems with their motors could simply fix them this way.

      [​IMG]
       
    17. Ricardo Brennan

      Ricardo Brennan New Member

      Joined:
      August 10, 2010
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      You can remanufacture like this and hope it works for awhile. I called Central Florida Mobile Power Window Repair and got a new power window regulator and motor installed for less than $160 while I was at work out in the parking lot. They gave me a warranty on the parts and labor. Their number is 407-415-5401
       
    18. 96_sport_ct

      96_sport_ct New Member

      Joined:
      August 2, 2010
      Messages:
      46
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Florida
      Year and Model:
      96 Sport control trac 4wd
      well considering i only had the problem with the motor its definitely worth the $15 to do both sides. both motors work like new now. i wouldn't mess with the regulator because i know of the dangers but i would imagine that most window related problems are from the motor considering that the regulators are pretty solid and the motor has weak plugs as well as a plastic gear inside. thanks lunchboxx for this amazing write up
       
    19. Project95

      Project95 New Member

      Joined:
      April 29, 2008
      Messages:
      14
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Wilmington, NC
      Year and Model:
      1995 Explorer Sport
      Dude!

      Guys, thanks SOO much for posting this! This saved me lots of "MONEY" buy DIYing it the Ford dealer wanted $95 an hr plus $120 for the motor which I got at autozone for $33.99 at the link below. 10 mins later and I few swear words because I keep dropping the screws inside the door but no bloody knuckles.

      thanks

      Project95

      http://www.autozone.com/autozone/pa...temIdentifier=54823_0_1264_78656&sortType=low
       
    20. MUL8KC

      MUL8KC New Member

      Joined:
      November 14, 2010
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Mobile, AL
      Year and Model:
      '96 XLT
      Electric Window Motor Bushings

      How do you get the window up (out of the way) when it fails in the down position? I've heard that removing the motor with the window down can be dangerous as the regulator has a spring?

      MUL8KC
       
    21. vett82ce

      vett82ce New Member

      Joined:
      March 28, 2007
      Messages:
      14
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Rincon,GA.
      Year and Model:
      '95 XLT
      Hey,
      I'm bringing this post back because someone referred me to it for my passenger side window that was not operating. I utilized the original post and it worked great but I took it to the poster's next level and removed the armature for cleaning. He was right - there was to much chunk in there to make me comfortable for leaving it there.

      Anyway, got a perplexing problem because I'm not electrically inclined. After wrestling with the brushes and springs for a while I finally got it done and the window operates beautifully except that up is down now and down is up?? From the switch on the armrest when I press the up button the window goes down and when I press the down button the window goes up. Obviously I missing something in putting back together an electric motor. It sure seems straight forward - remove armature from housing, clean, spring load your brushes and return armature. Any ideas?
       
    22. CDW6212R

      CDW6212R Elite Explorer

      Joined:
      June 17, 2004
      Messages:
      14,337
      Media:
      3
      Albums:
      1
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Knoxville, TN
      Year and Model:
      98 Mountaineer AWD
      I don't know what was changed in the motor, but the easiest way to switch that is to swap the two wires on the back of the switch. Check the other windows, and the right switch too(RF). The individual switch wires are relatively easy to remove and replace. Pull the windows fuse first though.

      The wires go into the large connector on the back of the switch. It takes just a tiny screwdriver to get those terminals out.
       
    23. vett82ce

      vett82ce New Member

      Joined:
      March 28, 2007
      Messages:
      14
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Rincon,GA.
      Year and Model:
      '95 XLT
      Got this solved. the housing can be put on 180 degrees the other way. One way makes it reverse on the switches and the other way makes it turn correctly.
       
    24. Robert Nick

      Robert Nick Member

      Joined:
      April 2, 2001
      Messages:
      97
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Brentwood TN
      Year and Model:
      '92 4WD XLT / 2000 Mounty
      I think you reversed the Brush Positon at the Commutator. DC Motors are designed to work in both directions. I think reversing the wire position that was previously mentioned is a better then taking everything apart to reverse the brushes.
       
    25. vett82ce

      vett82ce New Member

      Joined:
      March 28, 2007
      Messages:
      14
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Rincon,GA.
      Year and Model:
      '95 XLT
      No, actually the brushes can't be reversed. They won't reach from one side to the other. There's only one way of putting that thing back together and that's back the way it came apart with the exception of turning the cap 180 degrees.

      I did notice when putting the cap on the wrong way (it worked but my switches were reversed) there was no magnetic pull down on the cap. But, when it is turned the correct way - the magnetization literally slams the cap down hard. It literally pulled from my hand onto the base.
       
    26. Wade99

      Wade99 New Member

      Joined:
      April 29, 2011
      Messages:
      42
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Palm Harbor, FL
      Year and Model:
      99
      Free "bump" for a great post. I don't get the whole "drilling a hole to get at a bolt" because you sure don't have to do it in a Mustang. Both front windows of my 96 don't work. Well, the drivers side does go down with "help." The passenger side door switch wont even activate the motor, but I can from the drivers side.

      Anyhoo, great comical write up and I will be doing this fix once again. Will say this tho: It sure is a booger getting the cap back on the motor with three new bushings. I cursed a bunch when I did my Mustang motors.
       

    Share This Page


    Click Here

    We Support Our Troops!