I've got a '97 AWD with a healthy rain leak in the passenger rear-most side window. I hate to foul up the exterior with some sort of sealant, so I'd like to remove the trim, fix the leak, and replace the trim. Has anyone done this before? If so, what's the secret to removing the black plastic trim (without destroying the trim)?

Thanks!

 

I have the same problem on my 91, and I'm getting ready to repair it. I still have my 90 sitting next to the 91 and the 90 has all the interior trim removed. The window is part of a frame that is bolted through the vehicle skin. It looks like the outside trim is part of this frame.

You will have to loosen your trim on the inside and pull the trim back so that you can get at the fasteners. Once you remove the nuts you should have someone outside the vehicle as you push and pry the frame to unseat the sealer and push the window, frame, et al to the outside. Then reseal and install......

 

Here are instructions from the Ford CD.

Body Side Window/Sliding Side Door Glass, Aerostar

CAUTION:
Avoid damaging window assembly if it is to be reused.

Removal

1. Remove the quarter trim panel (31012).

2. Remove the retaining nuts from window module.

3. With an assistant to prevent damage, push the window out carefully.

Installation

1. Clean the window opening surface of all sealer.

2. Clean existing sealer from window module, if reusing.

3. Apply a continuous strip of 8-9mm (11/32 in.) bead of Liquid Butyl Sealer C9AZ-19554-B or equivalent meeting Ford specification ESB-M4G162-A.

4. Install the window module into the opening.

5. Install the retaining nuts. Tighten to 1-2 N-m (9-17 lb-in).

6. Test for water leaks.

7. Install quarter trim panel.

 

i had a leak on the passenger back window on my 91. after removing the interior trim panel i was able to access those nuts on the window trim. instead of removing and resealing, i just tightened them all up snug again, trying to do it equally around the window. i was suprise how loose they had gotten.that must have allowed the rain to get in. the leak stopped after that. rick