Fulltext TSBs

Technical Service Bulletins

TSB
04-5-7
  • BODY – FRONT WINDOW(S) – POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER’S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION
Publication Date: March 11, 2004

FORD:
1997-2003 F-150
1997-2004 EXPEDITION
LINCOLN:
1998-2004 NAVIGATOR

ISSUE:

Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver’s door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating.

ACTION:

To service, adjust the window’s travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below.

SERVICE PROCEDURE

  1. Remove inner door panel, refer to Workshop Manual Section 501-11.
  2. Remove exterior mirror, refer to Workshop Manual Section 501-09.
  3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N-m (8 lb-ft).
  4. Lower door glass to position it out of the way.
  5. Remove inner and outer belt molding.
  6. Position aside front window run.
    1. Remove retainer.
    2. Position outside of work area.
  7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10″) (Figure 2).

    NOTE:TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE.

  8. Reposition front window run.
    1. Install retainer.
    2. Torque retainer to 11 N-m (8 lb-ft).
  9. Install inner and outer belt molding.
  10. Install exterior mirror, refer to Workshop Manual Section 501-09.
  11. Install inner door panel, refer to Workshop Manual Section 501-11.
  12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11.

    LABOR OPERATION CLAIMING CHART
    OperationLabor DescriptionApplicationTime
    040507AAdjust Window Travel Path By Bending Flange One Front Door: (Includes Time To Remove Mirror And Interior Door Trim Panel)1997-2004 Expedition
    1998-2002 Navigator
    1997-2003 F-150
    0.6 Hr.
    0.6 Hr
    0.5 Hr.
    040507BAdjust Window Travel Path By Bending Flange Both Front Doors: (Includes Time To Remove Mirror And Interior Door Trim Panel)1997-2004 Expedition
    1998-2002 Navigator
    1997-2003 F-150
    1.2 Hrs.
    1.2 Hrs.
    0.9 Hr.
    040507CAdjust Window Travel Path By Bending Flange Drivers Front Door Only: (Includes Time To Remove Mirror And Interior Door Trim Panel And To Perform The Door Window Initialization Procedure Twice On The Drivers Door Only)2003-2004 Navigator0.8 Hr.
    040507DAdjust Window Travel Path By Bending Flange Passenger Front Door Only: (Includes Time To Remove Mirror And Interior Door Trim Panel)2003-2004 Navigator0.6 Hr.
    040507EAdjust Window Travel Path By Bending Flange Both Front Doors: (Includes Time To Remove Mirror And Interior Door Trim Panel And To Perform The Door Window Initialization Procedure Twice On The Drivers Door Only)2003-2004 Navigator1.3 Hrs.

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

DEALER CODING

BASIC PART NO.CONDITION CODE
782012542



Figure 1 – Article 04-5-7




Figure 2 – Article 04-5-7


NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright 2004 Ford Motor Company