Couple of months ago my driver's window would not work sometimes. If i pressed the button just right it would work. Then one day they all stopped working completely. I replaced the #14 circuit breaker. Nothing. I replaced the switch cluster. Nothing. Looked at the old switch for the drivers side window - the contacts were black and the plastic pin that normally pushes the contact down - well....it was melted and mostly gone. Is there a relay or fuse that i have overlooked somewhere? what now?

 

See if you can check the ground point for that circuit(s).....loose or corroded grounds will cause excessive current draw, so it might be worth taking a look

 

Do you think that ground will be in the door panel or under the hood?

 

Gordon -

Any luck in finding out the problem? My windows on a '05 EXPY EB are all slowing down intermittently. Some days they are normal, others day they are slower than slow.. Just wondering if you had any leads ?

 

I'm in the auto glass business and it sounds like everyone so far is having an issue with the electric motors moreso than just switches, fuses or ground connections. The slow operation and/or complete failure along with melted and darkened switch suggests the motors are beginning to fail.

Grounds for window motor circuits are typically inside the wire harness which ultimately runs to the body. Finding a good condtion OEM EVTM (Electricial/Vacuum Troubleshooting Manual, FleaBay) for your specific vehicle would be your best bet. Typically there are only two things that cause power windows to behave like this----binding of the glass in its run channels or failing motor. Assuming no one has trie "fixing" things and damaged the wiring or perhaps collision damage problems can typically be isolated to the switch or the motor.

IF it comes to replacing the motor its part of the regulator mechanism and relatively simple to replace----over in the Vans forum myself and one other member have posted suggested methods for replacing these assemblies. In the event the regulator/motor is changed PLEASE use a wet type silicone lubricant (3M 08877 or similar) in the run channels the entire length the glass travels. Also, Ford's OEM assemblies are fairly priced at less than $150 each and for the work involved its a good investment over used or Chinese junk found in the auto parts stores. Keep in mind the drivers side door will be the first to go since its used constantly the small extra cost of good parts makes it worth it IMHO.

I'm glad to help any way I can so do be bashful about PM'ing me or posting here again.

Best of luck--hope this is helpful!