AAGGHHHH!!

Why is my aerostar beginning to break-down?

Could it be that the wife is trying to tell me something
[she drives it more than I do]

she lowered the driver side window and tried to close it..
it stopped 3/4 of the way ... 1/4 of window open

and...

to top it off ... the switch flew off AAGGHHHH!!

more help please...

thanks

Gary

 

Well first replace the switch you can pick one up at the Ford dealer or I've heard Napa has them as well. If you decide to go the Ford dealer route order it from fordparts.com since they for some reason are alot cheaper then the local Ford dealers after shipping too.

As for the window getting stuck after the switch is replaced try bringing it down does it go down? Or do you just hear the motor and there is no movement?

If the window goes down and when you bring the window up the motor sounds like it struggling and slowly stopping bring the window down and buy a can of silicone lube and spray it in the window track the top, left, and right channels. Then run the window up and down to spread the lube and that should solve your problem.

If the window doesn't go down or the lube doesn't solve your problem you'll need to replace your window regulator.

Doing this is a little difficult since there are rivets retaining the window glass and the regulator to the door body and you'll have to drill them out. So you want make sure you have time set aside for this.

First things first how to remove the trim panel.

Trim Panel, Door, Front

Removal and Installation

1. Remove the window regulator handle (1 screw).

2. Remove the screw at the arm rest (24140).

3. Remove two screws on the switch plate housing or front door trim panel (23942).

4. Remove the switch plate housing or front door trim panel.

5. Remove the screw under the arm rest.

6. Insert hand tool (part of Rotunda Windshield and Moulding/Trim Removal Kit 107-R0401, or equivalent) behind the pushpins. Partially pry the pins out of the sheet metal holes using the sequence shown in the following illustration.



7. Remove and discard all pushpins from the front door inner panel sheet metal.

8. Remove the front door trim panel from the front door (20124).
For installation, follow removal procedures in reverse order. Replace pushpins with new pushpins.





Now you can remove the window glass be careful while drilling the rivets out on this one.

Door Window Glass Removal Aerostar

Removal

1. Remove front door trim panel (23942) and front door trim shield (237A04).

2. Raise front door window glass (21410) to full up position.

3. Remove rear glass run retainer from front door (20124).

4. Lower front door window glass to gain access to front door window channel bracket and glass retention rivets.

5. Note: Use care when drilling not to damage glass bracket and spacer/retainers.

Remove center pin from the glass retention rivets using a drift punch. Then, use a 6.35mm (1/4-inch) diameter drill and drill out each rivet.

6. Remove the front door window glass through the door window opening.

Installation

1. Install spacer and retainer into glass retention holes.

2. Install front door window glass into front door through the door window opening.

3. Position the front door window glass to the front door window channel bracket and align with the retaining holes.

4. Install retaining rivets.

5. Raise front door window glass to full up position.

6. Install the rear glass run retainer.

7. Cycle front door window glass up and down to check operation.

8. Install front door trim shield and front door trim panel.

Now to remove the regulator:

Now at last you can get to the regulator and drill out the 4 retaining rivets (3 for manual) securing it to the door.

Window Regulator, Aerostar

Front Door

Removal

1. Note: Refer to illustration in Removal and Installation, «Door Window Glass, Ranger, Aerostar».

Remove the front door trim panel and front door trim shield. Refer to «Section 01-05B».

2. If equipped with power windows, disconnect the wire from the window regulator electric drive.

3. Remove the front door window glass (21410) as described in this section.

4. Remove the front door glass run latch side retainer, if equipped (one screw), and remove it through the door window opening.

5. Remove the glass bracket assembly, from the front door (20124), sliding the bracket C-channel off the regulator arm side/roller.

6. Note: Be careful not to damage sheet metal holes during drilling.

Remove the center pin from the regulator attaching rivets (three for manual, four for power) with drift punch. Then, drill out remainder of rivet heads using a 6.35mm (1/4-inch) drill.

7. Remove the window regulator from the front door.

Installation

1. Position the window regulator in the front door. Align retention holes to door inner panel.

2. Install three (four rivets for power window) rivets attaching the window regulator to door inner panel using Rotunda Blind Fastener Installation Tool 107-R0600 or equivalent. Equivalent threaded fasteners may be used in place of rivets.

3. Assemble glass bracket to regulator arm slide.

4. Install front door window glass as described in this section.

5. Install the front door glass run latch side retainer. Make sure the front door window glass is seated in the retainer's C-channel.

6. Adjust the front door glass run latch side retainer so that the front door window glass can move freely but not loosely.

7. Tighten the front door glass run latch side retainer bolt to 7-11 N-m (62-92 lb-in).

8. Reconnect wire to regulator for power window if equipped.

9. Check operation of window regulator.

10. Install front door trim shield and trim panel.

Parts Breakdown Of The Window Regulator (Manual And Power)

 

Krankshaft, excellent work! Those photos and part locations are extremely helpful. I also want to say, always have a new set of pushpins available. Unless they are near new, the first time you pry them out for doing any repair / maintenece work inside the door, the old pushpins never give the proper "sealing" for the door panel. There is annoying gaps. With new pushpins, they bite in and secure the panel for a flush & tight seal. Just my 2 cents...always lubricate the roller mechnisms for the windows (power or manuel) so the window raises or lowers quietly. With power windows, this simple task greatly helps the power motor, especially those Aerostars exposed to freezing temperatures in the winter, as well as high humidity and salt air, those vans from the coastal areas of the USA & Canada. ED

 

also check the wires where they enter the door post. I was getting intermittent problems with the windows, door locks, etc. then suddenly, one by one, stuff started dying for good. in searching for the problem, I found half of the wire harness cut....most likely what happened was that at some point, the rubber "tube"/grommet they are contained in where they pass from the door to the door pillar/passenger compartment, had come loose and some of the wires were cut/damaged and over time this damage was worsened by opening and closing the door, finally breaking the wires completely. had to pull the entire door harness and replace the damaged sections.