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Explorer, Sport Trac, Mountaineer & Aviator 1991-1994, 1995-2001, 2002-2005, 2006-2010 Ford Explorer

92 explorer window blues

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Old Feb 3, 2006 | 10:42 PM
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JWM111654's Avatar
JWM111654
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92 explorer window blues

I'm having major window problems. 3 of my 4 windows are not working. I had to put a screw in them to keep them up. I need to open my driver's window to pass security gate at work. I have to open my door and hang my head out.

Does anyone have a diagram of the window components. 92 explorer eddie bauer 2x4 electric windows.
 
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Old Feb 3, 2006 | 11:49 PM
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Torque1st
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Hello- Welcome to FTE!

The most common cause of window failure in Ford power windows is the plastic rollers in the clutch assy. If the front window motors still run, but the window does not go up and down, (you may hear a clicking noise from the mechanism) you can try the following. Check with your repair manual to see if I have left anything out:

Pull the front door panel. Move the glass to the full up position and support it. Near the speaker you will see a couple of 1/2" diameter holes with small bolts showing inside them. Nearer to the speaker you will see a "dimple" in the inner door. Drill a 1/2" diameter hole at that location. (Sometimes you get lucky and all three holes are there from a previous repair.) That hole will reveal another small bolt head just like the other two holes did. Pull the small gray 2-wire connector apart just a few inches below the hole. Remove all three bolts and remove the window motor from the door.

Remove the last button head torx screw from the motor cover. Remove the cover. Remove the "C" clip from the gear shaft. Remove the drive gear. Remove the O-ring from the shaft groove. Remove the worm gear and clutch mechanism. Clean the housing with brake or carb cleaner and blow out any plastic chips (if you have compressed air). Inspect the worm shaft for missing or broken teeth (looks like a threaded shaft). If there are broken teeth go to the parts store and get a new motor assy. Inspect the outside of the plastic gear assy for missing or broken teeth. If any are broken etc go to the parts store and get a new gear assy. If no teeth are missing or broken clean the gear with carb cleaner etc to remove all of the broken plastic shards. Clean the cover. Use brake caliper synthetic grease and lubricate the worm shaft in the center. Lubricate the plastic gear all the way around with synthetic grease and work the grease into the teeth with your finger. It does not take a LOT of grease. put a small amount of grease on the shaft and housing. Insert the plastic gear, replace the O-ring. Smear a dab of grease into all three lobes in the center of the plastic gear to lubricate the ball bearings and to hold them in place during assy. Place three 3/8" or 10MM steel ball bearings into the lobes (this will not be necessary if you have a new assy). Ball bearings can be purchased at a hardware store. Clean the drive gear and lubricate with a small amount of the synthetic grease. Replace the gear on the shaft, it should drop in with the three ball bearings in between the "lobes" (or the new plastic rollers). Replace the "C" clip. Lubricate the cover in the center and around the outside. Replace the cover and screw. Replace the motor in the door and reconnect the wires.

I have not done this to rear doors. I think they are similar.
 

Last edited by Torque1st; Feb 3, 2006 at 11:53 PM.
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