How do you Change, Replace, or Install Broken 1991-2005 Ford Explorer, Sport Trac, Mercury Mountaineer Power Window Regulator Replacement
Fits years: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
- 10mm socket/ratchet
- 11mm socket/ratchet
- Phillips screwdriver
- Flathead screwdriver
- Drill with small/large drill bits
- Bolts/nuts for rivet replacement
- Tape (Painter's tape recommended)
NOTE: When removing the door panel in this installation, your particular model year may be SLIGHTLY different than what is outlined in this installation. The general process will be the same, though the number of screws, or the type of screws/bolts, may be different!
Step 1: Open the vehicle's door.
Step 2: Using the flathead screwdriver, pry and remove the bezel that surrounds the interior door handle. Loosen and remove the Phillips screws (2) exposed by removing the bezel.
Step 3: Pry and remove the mirror control switch. Disconnect the wiring harness attached to the back of the switch.
Step 4: Using the door panel clip tool (or putty knife), pry and remove the interior door panel from the door frame.
A series of retaining pins holds the interior panel to the door frame. Slide the tool between the panel and the door, slide along until you feel a pin, then pry out to release the pin. You will hear it "pop" as it disengages.
Step 5: You can now lift and remove the interior door panel.
Step 6: Disengage the power window panel by releasing the tabs, and slide this switch-plate from the interior door panel.
Step 7: GENTLY peel the water shield from the door frame. Be careful not to tear it, as we'll need to reattach it later!
Step 8: Using a hammer/punch, create a drill point on the joint where the window regulator meets the track.
Step 9: Using the drill and a small bit, drill into the divot created in Step 8. Gradually increase the bit size, drilling into the same hole, until you are able to break the joint.
Step 10: Use the hammer/punch to break the rivets (4) that secure the regulator to the door frame. You can now use a larger drill bit to fully puncture the rivet.
Step 11: Loosen and remove the 11mm bolts (3) that secure the regulator to the door frame.
Step 12: Using the hammer/punch, completely remove the rivets drilled in Step 10. Again, BE CAREFUL!
Step 13: Disconnect the window motor's wiring harness (1).
Step 14: Lift the window from the track, and secure it with tape to the TOP of the window frame. This keeps it out of the way.
Step 15: Punch and drill the rivets (2) at the TOP of the regular to allow for the assembly's removal.
Step 16: Loosen and remove the Phillips screws (2) that secure the interior door handle to the door frame. Slide the assembly toward the HINGE side of the door. Release the retaining clip on the BACK of the assembly to allow for its removal.
Step 17: You can now slide the window regular from the door frame.
Step 18: Insert the new window regular into the door frame.
Step 19: Using NEW bolts/nuts, secure the window regular to the door frame. The bolt/nut combinations should be used anyplace where we drilled out rivets.
Step 20: With the assembly mounted to the door, connect the window motor's wiring harness.
Step 21: SLOWLY slide the window panel down onto the regulator track. Tighten the 11mm mounting bolts to secure the regulator. You can now reattach the water shield.
Step 22: Reattach the interior door handle to the door frame.
Step 23: Reattach the power window switch-plate to the interior door panel.
Step 24: Reattach the interior door panel by re-engaging all of the retaining pins.
A firm strike on the door panel just over each pin should do the trick! Don't damage your door panel, though, as it doesn't take much force!
Step 25: Reconnect the mirror control switch's wiring harness.
Step 26: Tighten the Phillips screws (2) near the interior door handle.
Step 27: Reattach the interior door handle's bezel.
91 1991, 92 1992, 93 1993, 94 1994, 95 1995, 96 1996, 97 1997, 98 1998, 99 1999, 00 2000, 01 2001, 02 2002, 03 2003, 04 2004, 05 2005 Ford Explorer Window Regulators & Motors Replacement Instructions
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