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Power Window Bushing Replacement with Pics

Discussion in 'Stock 1991 - 1994 Explorers' started by 85Dave, October 25, 2005.

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  1. 85Dave

    85Dave Active Member

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    The power windows on my 92 quit going up and down. The motor would make noise, but the window wouldn't move. There are 3 plastic bushings inside the gear drive of the power window motor that crumble. This is my step-by-step replacement with pics.

    First, open the door. On my 92, it was the left rear.
    [​IMG]
     
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  3. 85Dave

    85Dave Active Member

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    Remove the 2 screws above the pull handle. I'm using an electric screwdriver to make the job go quicker.
    [​IMG]
     
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  4. 85Dave

    85Dave Active Member

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    Then pry out the face plate.
    [​IMG]
    [​IMG]
     
  5. 85Dave

    85Dave Active Member

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    Then pry off the door panel. I used a wood chisel wrapped with duct tape.
    [​IMG]

    Work your way around the sides and bottom.
    [​IMG]

    Remove the door panel by lifting up and away. Unscrew the switch and move the door panel out of the way.[​IMG]

    Remove the speaker screws.
    [​IMG]

    Remove the speaker and wiring.
    [​IMG]

    Remove the speaker housing.
    [​IMG]
     
  6. 85Dave

    85Dave Active Member

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    Peel back the dust shield.
    [​IMG]
     
  7. 85Dave

    85Dave Active Member

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    There are 3 bolts that have to be removed. There are access holes for 2 of them. The third hole has to be drilled with a 1/2 hole. There is a dimple where the 3rd hole needs to be drilled.
    [​IMG]
    [​IMG]
     
  8. 85Dave

    85Dave Active Member

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    I used a small flathead screwdriver to remove the bolts. Your bolts may vary.
    [​IMG]

    I also used a magent to get the last bolt out.
    [​IMG]
     
  9. 85Dave

    85Dave Active Member

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    Disconnect the wiring harness to the power window motor.
    [​IMG]

    And remove the motor. I had to fiddle with the motor to get it out. Push it towards the outer door panel.
    [​IMG]
     
  10. 85Dave

    85Dave Active Member

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    You now have to remove the gear cover. Its the black part of the housing. This one was held in place with some screws. The fronts were a little different.
    [​IMG]
     
  11. 85Dave

    85Dave Active Member

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    Remove the cover, and you'll see all the little bits and pieces of the old bushings.
    [​IMG]

    Remove the metal gears by lifting up. The front windows had a c-clip that had to be removed first.
    [​IMG]
     
  12. 85Dave

    85Dave Active Member

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    Remove the plastic gear by turning upside down and tapping. Clean up.
    [​IMG]

    Clean up the housing.
    [​IMG]
     
  13. 85Dave

    85Dave Active Member

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    Re-install the plastic gear. I put some fresh grease on it.
    [​IMG]
     
  14. 85Dave

    85Dave Active Member

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    Now comes the tricky part. Put the 3 bushings on the metal gear, and carefully work into place. On the front units, I had to shave the bushings down a little because the fit was too tight. The bushings came from Autozone in a "Help" blister pack. About $5 or so.
    [​IMG]
    [​IMG]
     
  15. 85Dave

    85Dave Active Member

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    Put the cover back on.
    [​IMG]
     
  16. 85Dave

    85Dave Active Member

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    Put the motor back into place and re-install the 3 bolts.
    [​IMG]
     
  17. 85Dave

    85Dave Active Member

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    Spray some glue on the door panel...
    [​IMG]

    ...and put the dust cover back in place.
    [​IMG]

    Make sure you line up the holes.
    [​IMG]

    Some of the fastners were stuck in the door frame. Remove these and put them in the door panel.
    [​IMG]
     
  18. Chew_12

    Chew_12 Working

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    Awesome! Nice write up!
     
  19. Glacier991

    Glacier991 EF Tranny Guru Moderator Emeritus

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    EXCELLENT POST. I am about to do this, and was going to muddle through based on some other good writeups, but your pictures will be a HUGE help! I nominate this for Useful Threads, and vote it 5 stars!
     
  20. 85Dave

    85Dave Active Member

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    Re-install the speakers, window switch, and door panel. Your done and can now enjoy a frosty adult beverage knowing that you just saved a bunch of money.

    The first door tood about 1.5 hours, and the second door took about 45 minutes. I also did the front units. The method was very similar, but a few details were different such as the location of the dimple and the gear housing screw and c-clip.
     
  21. 85Dave

    85Dave Active Member

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    Just trying to pay back some of the excellent information I've gotten from this forum. :chug:
     

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