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Power Window Bushing Replacement with Pics

85Dave

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City, State
Germantown, TN
Year, Model & Trim Level
92 XLT
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.
door.jpg
 


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85Dave

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City, State
Germantown, TN
Year, Model & Trim Level
92 XLT
Remove the 2 screws above the pull handle. I'm using an electric screwdriver to make the job go quicker.
handle-screws.jpg
 




85Dave

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92 XLT
Then pry out the face plate.
handle-plate1.jpg

handle-plate2.jpg
 




85Dave

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92 XLT
Then pry off the door panel. I used a wood chisel wrapped with duct tape.
panel-remove.jpg


Work your way around the sides and bottom.
panel-remove-2.jpg


Remove the door panel by lifting up and away. Unscrew the switch and move the door panel out of the way.
window-switch1.jpg


Remove the speaker screws.
speaker1.jpg


Remove the speaker and wiring.
speaker2.jpg


Remove the speaker housing.
speakerhousing1.jpg
 




85Dave

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92 XLT
Peel back the dust shield.
dustshield1.jpg
 




85Dave

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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.
Dimple.jpg

dimpledrill.jpg
 




85Dave

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I used a small flathead screwdriver to remove the bolts. Your bolts may vary.
motorbolt1.jpg


I also used a magent to get the last bolt out.
motorbolt2.jpg
 




85Dave

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92 XLT
Disconnect the wiring harness to the power window motor.
motorconnector.jpg


And remove the motor. I had to fiddle with the motor to get it out. Push it towards the outer door panel.
motor-remove.jpg
 




85Dave

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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.
gearcover1.jpg
 




85Dave

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Remove the cover, and you'll see all the little bits and pieces of the old bushings.
old-bushings.jpg


Remove the metal gears by lifting up. The front windows had a c-clip that had to be removed first.
old-bushings2.jpg
 




85Dave

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Remove the plastic gear by turning upside down and tapping. Clean up.
plastic-gear.jpg


Clean up the housing.
motor-housing.jpg
 




85Dave

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Re-install the plastic gear. I put some fresh grease on it.
gear-install.jpg
 




85Dave

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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.
gear-install2.jpg

gear-install3.jpg
 




85Dave

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Put the cover back on.
cover-intall.jpg
 




85Dave

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Put the motor back into place and re-install the 3 bolts.
motor-install.jpg
 




85Dave

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Spray some glue on the door panel...
spray-glue.jpg


...and put the dust cover back in place.
dustshield2.jpg


Make sure you line up the holes.
dust-shield-align.jpg


Some of the fastners were stuck in the door frame. Remove these and put them in the door panel.
Fastners-replace.jpg
 




Chew_12

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City, State
Chandler, AZ
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'93 XLT
Awesome! Nice write up!
 




Glacier991

EF Tranny Guru
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Year, Model & Trim Level
1992 XLT
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!
 




85Dave

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92 XLT
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.
 


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85Dave

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City, State
Germantown, TN
Year, Model & Trim Level
92 XLT
Glacier991 said:
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!
Just trying to pay back some of the excellent information I've gotten from this forum. :chug:
 




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