Here it is late summer of 1998 and the front left (drivers) electric window on my 1991 Explorer quits working. This didn't seem to be much of a problem as I could still hear the motor running when I activated the window switch, the window just would not go up or down. I removed the window lift motor assembly and found that the motor's nylon gear mechanism was shot. I visited a couple of the local parts houses and found that they could not obtain any replacement parts for the lift motor. However they could supply a complete window lift motor assembly for around $60.00. While visiting my local Ford dealer, I found that they too did not offer any replacement parts other than a complete window lift motor assembly. Fortunately, they did have a Ford remanufactured window lift motor in stock and it too was approximately $60.00. Since the price was basically the same and the unit was in stock, I purchased it and installed it the very next day.
After replacing the, every time the window was completely moved to the top or bottom position a loud clunk would result. I didn't like this but at least the drivers window worked again (just try going through a toll booth when this window doesn't work! My kids loved it as they got to throw the change from the rear window) Then much to my horror, all of the other three windows quit working with in the next week or so. Since I wasn't real happy with the Ford remanufactured window lift motor operation, purchasing additional units from Ford seemed unwise and it also appeared to be very expensive. It was then that I happened across South Florida Window Lift on the Internet. They specialize in remanufactured automotive electric accessory motors and had the replacement gears in stock for only $15.00 each. Their web address is South Florida Window Lift
I purchased four sets of gears and they shipped them to me COD. I also replaced the gear that came installed in Ford remanufactured window lift motor. Now all four windows are operational at a substantial savings over the cost (and subsequent aggravation) of replacement complete motor units.
Additionally, to remove one of the window lift motor mounting screws it is necessary to drill a 1/2" (or larger depending on the OD size of the socket wrench or nut driver used) at the drill dimple point located over the screw head.
Two areas of caution:
1. Grease the gears sparingly as too much grease can get into the electrical brushes of the motor and cause additional headaches when the motor becomes inoperable due to the excess grease that must be carefully cleaned out of the motor brushes.
2. Makes sure the motors electrical harness is positioned correctly on the rear windows as if it is in the wrong place it will be snagged by the window as it is moving to the full down position. Check this operation carefully to confirm the harness placement prior to reassemble by working the motor up-and down and verify that the wiring does not get snagged.
This past weekend I pulled out a malfunctioning driver's side power window motor from my 91 (195K). The three little plastic cylinders in the gear assembly that transfer power from the large plastic gear to the metal gear had been crushed and turned into plastic-grease mush. It cost me 48 cents plus tax and about 30 minutes to fix it:
Or buy three 10mm x 12mm nylon spacers - if you can find them. Open beer, then open window.
Contributed by Kirk G.I stumbled upon your tip for the Power windows on the 91 Ford Explorer. I too went around all over the place looking for the gears.. no such animal, and the dealer only sales the whole kit.. $180. Well here's what I did, as an experiment, I bought one of the gears from Pepboys, took a flat head screw driver and lifted up the center piece out of the gear (it's loose, on the original it's the same way) comes out easily, took the 3 little pieces put it in my gear.. presto good as new.. only costs $8.75 at Pepboys
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I also had the passenger front window quit working and the replacement parts were backordered but I found a shadetree mechanics quick fix. After removing the motor ass'y from the door and disassembling it, I placed 3 small ball bearings in the space between the plastic gear and the inner triangular shaped metal gear. Grease her up, reinstalled the motor and we have a working window again. Total cost $00.00! There's a lot to say for keeping all those misc. pieces and parts in what I call my 20 year box. Some time in the next 20 years I'll need it.
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