Haunted Power Windows
Al;
I have been to he11 and back with power window problems when I first bought my Mounty three years ago. I finally bought the Ford workshop manual on CD which has detailed wiring diagrams.
When the problem occurs, if the window will NOT function from either the master switch OR the switch on the door in question, it is almost ALWAYS a break in the ground loop. The fact that the problem comes and goes is indicative of a break in the wiring that makes intermittent connection based upon hitting a bump in the road, whether or not it is raining, or how hard you close a door. There are two places where the wiring typically breaks. It is the connector behind the driver side kick plate and the neoprene weather boot in the driver's door jamb. Far down on the list is the boot on the other three doors simply because they aren't opened and closed as often as the driver door and they are less crowded with cabling. so there is less friction on the insulation.
Since you said it sometimes corrects itself when you open and close the driver's side door, it is a 99.998% probability that you have a broken wire in the boot. I had exactly the same symptom. If the passenger window wasn't working, I'd open and close the driver's door and it would work for several days. It almost always seemed to work when it was raining.
I made a 15 foot cable out of 12 gauge twin conductor speaker wire (it was what I had on hand at the time) with battery clamps on one end and electronic equipment alligator clips (the kind where you can insert a probe in the ends) on the other. After removing the door panels, this allowed me to supply 12V and ground to any portion of the circuit to check the operation of the switches, motors and cabling. When I connected the ground to the master switch, the passenger window would work with fail.
If I remember correctly, this was the green/black wire on the master switch. I pulled the boot in the drivers door by cutting the plastic security tie on the bottom of the boot and sliding it up as far as it would telescope.
I found the wire and gave it a little tug and it pulled right out. Luckily, I could grab the end going into the foot well and pull it out about half an inch. I scraped off a quarter inch of insulation and soldered in a one inch piece of wire to jump the break. The other end of the one inch piece, I soldered to the end of the wire coming out of the door after sliding a length of shrink tubing on it. I slid the shrink tubing over the solder joints and shrank it with my wife's hair dryer.
I did this sometime early last spring and I haven't had a problem since.
Start simple. The door switches almost never break and when they do, they just stop working. The problem will not come and go.
That being said, if I'm wrong, (and I have been known to be wrong at times. Just ask my wife!) I have a working master power window switch in my workshop that came out of a 97 Thunderbird that you can have for free. Believe it or not, the Thunderbird power window switches are identical to the Explorer/Mountaineer power window switches right down to the part numbers.
NJMike
