1991 1999 ford explorer chilton User Manual
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REMOVAL & INSTALLATION Glass Door glass-RangerClick to enlarge HOW TO USE THIS BOOK 1124 REMOVAL & INSTALLATION
Front door glass-Explorer Click to enlarge HOW TO USE THIS BOOK REMOVAL & INSTALLATION 1125
Rear door glass-Explorer Click to enlarge Remove the door trim panel and speaker if applicable. 1. Remove the screw from the division bar. Remove the inside belt weatherstrip(s) if equipped. 2. Remove the 2 vent window attaching screws from the front edge of the door. 3. Lower the glass and pull the glass out of the run retainer near the vent window division bar, just enough to allow the removal of the vent window, if equipped. 4. Push the front edge of the glass downward and remove the rear glass run retainer from the door. 5. If equipped with retaining rivets, remove them carefully. Otherwise, remove the glass from the channel using Glass and Channel Removal Tool 2900 (made by the Sommer and Mala Glass Machine Co. of Chicago, ILL., or its equivalent). Remove the glass through the belt opening if possible. 6. To install: Install the glass spacer and retainer into the retention holes. 7. Install the glass into the door, position on the bracket and align the retaining holes. 8. Carefully install the retaining rivets or equivalent. 9. Raise the glass to the full closed position. 10. Install the rear glass run retainer and glass run. Install the inside belt weatherstrip(s). 11. Check for smooth operation before installing the trim panel. 12. HOW TO USE THIS BOOK 1126 REMOVAL & INSTALLATION
Regulator EXCEPT EXPLORER/MOUNTAINEER FRONT DOOR Power regulator-Ranger shownClick to enlarge Remove the door trim panel. If equipped with power windows, disconnect the wire from the regulator 1. Support the glass in the full UP position or remove completely. 2. Remove the window guide and glass bracket if equipped. 3. Remove the center pins from the regulator attaching rivets. 4. Drill out the regulator attaching rivets using a 1 /4 in. (6mm) drill bit. 5. Disengage the regulator arm from the glass bracket and remove the regulator. 6. Installation is the reverse of removal. 1 /4 in.-20 x 1 /2 in. bolts and nuts may be used in place of the rivets to attach the regulator. 7. EXPLORER/MOUNTAINEER FRONT DOOR HOW TO USE THIS BOOK REMOVAL & INSTALLATION 1127
Regulator-Explorer shown Click to enlarge Remove the door trim panel and watershield. 1. Remove the inside door belt weatherstrip and glass stabilizer. 2. Remove the door glass. 3. Remove the 2 nuts attaching the equalizer bracket. 4. Remove the rivets attaching the regulator base plate to the door. 5. Remove the regulator and glass bracket as an assembly from the door and transfer to a workbench. 6. Carefully bend the tab flat in order to remove the air slides from the glass bracket C-channel. 7. Install new regulator arm plastic guides into the C-channel and bend the tab back 90°. If the tab is broken or cracked, replace the glass bracket assembly. Make sure the rubber bumper is installed properly on the new glass bracket, if applicable. 8. CAUTION If the regulator counterbalance spring is to be removed, make sure the regulator arms are in a fixed position prior to removal. This will prevent possible injury when the C-spring unwinds. To install: Assemble the glass bracket and regulator assembly. 9. Install the assembly in the door. Set the regulator base plate to the door using the base plate locator tab as a guide. 10. Attach the regulator to the door using new rivets. 1 /4 in.-20 x 1 /2 in. bolts and nuts may be used in place of the rivets to attach the regulator. 11. Install the equalizer bracket, door belt weatherstrip and glass stabilizer. 12. Install the glass and check for smooth operation before installing the door trim panel. 13. Electric Window Motor REMOVAL & INSTALLATION Ranger Disconnect the negative battery cable. 1. Open the window. Remove the trim panel and watershield and support the window. 2. Disconnect the power window motor connector. 3. There may be a drill dimple in the door panel, opposite the concealed motor retaining bolt. Drill out the dimple to gain access to the bolt. Be careful to avoid damage to the wires. Remove the motor mounting bolts and remove the motor and regulator assembly. 4. Separate the motor and drive from the regulator on a workbench. 5. Installation is the reverse of removal. 6. HOW TO USE THIS BOOK 1128 Electric Window Motor
Check for smooth operation before installing the trim panel. 7. Except Ranger Raise the window fully if possible. If not, you will have to support the window during this procedure. Disconnect the battery ground. 1. Remove the door trim panel. 2. Disconnect the window motor wiring harness. 3. There may be a drill dimple in the door panel, opposite the concealed motor retaining bolt. Drill out the dimple to gain access to the bolt. Be careful to avoid damage to the wires. 4. Remove the motor mounting bolts (front door) or rivets(rear door). 5. Push the motor towards the outside of the door to disengage it from the gears. Youll have to support the window glass once the motor is disengaged. 6. Remove the motor from the door. 7. Installation is the reverse of removal. To avoid rusting in the drilled areas, prime and paint the exposed metal, or, cover the holes with waterproof body tape. Make sure that the motor works properly before installing the trim panel. 8. Windshield and Fixed Glass REMOVAL & INSTALLATION If your windshield, or other fixed window, is cracked or chipped, you may decide to replace it with a new one yourself. However, there are two main reasons why replacement windshields and other window glass should be installed only by a professional automotive glass technician: safety and cost. The most important reason a professional should install automotive glass is for safety. The glass in the vehicle, especially the windshield, is designed with safety in mind in case of a collision. The windshield is specially manufactured from two panes of specially-tempered glass with a thin layer of transparent plastic between them. This construction allows the glass to give in the event that a part of your body hits the windshield during the collision, and prevents the glass from shattering, which could cause lacerations, blinding and other harm to passengers of the vehicle. The other fixed windows are designed to be tempered so that if they break during a collision, they shatter in such a way that there are no large pointed glass pieces. The professional automotive glass technician knows how to install the glass in a vehicle so that it will function optimally during a collision. Without the proper experience, knowledge and tools, installing a piece of automotive glass yourself could lead to additional harm if an accident should ever occur. Cost is also a factor when deciding to install automotive glass yourself. Performing this could cost you much more than a professional may charge for the same job. Since the windshield is designed to break under stress, an often life saving characteristic, windshields tend to break VERY easily when an inexperienced person attempts to install one. Do-it-yourselfers buying two, three or even four windshields from a salvage yard because they have broken them during installation are common stories. Also, since the automotive glass is designed to prevent the outside elements from entering your vehicle, improper installation can lead to water and air leaks. Annoying whining noises at highway speeds from air leaks or inside body panel rusting from water leaks can add to your stress level and subtract from your wallet. After buying two or three windshields, installing them and ending up with a leak that produces a noise while driving and water damage during rainstorms, the cost of having a professional do it correctly the first time may be much more alluring. We here at Chilton, therefore, advise that you have a professional automotive glass technician service any broken glass on your vehicle. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 1129
WINDSHIELD CHIP REPAIR Check with your state and local authorities on the laws for state safety inspection. Some states or municipalities may not allow chip repair as a viable option for correcting stone damage to your windshield. Although severely cracked or damaged windshields must be replaced, there is something that you can do to prolong or even prevent the need for replacement of a chipped windshield. There are many companies which offer windshield chip repair products, such as Loctites® Bullseye windshield repair kit. These kits usually consist of a syringe, pedestal and a sealing adhesive. The syringe is mounted on the pedestal and is used to create a vacuum which pulls the plastic layer against the glass. This helps make the chip transparent. The adhesive is then injected which seals the chip and helps to prevent further stress cracks from developing Always follow the specific manufacturers instructions. Small chips on your windshield can be fixed with an aftermarket repair kit, such as the one from Loctite( HOW TO USE THIS BOOK 1130 WINDSHIELD CHIP REPAIR
Most kits use a self-stick applicator and syringe to inject the adhesive into the chip or crack Inside Rear View Mirror REMOVAL & INSTALLATION The mirror is held in place with a single setscrew. Loosen the screw and lift the mirror off. Dont forget to unplug the electrical connector if the truck has an electric Day/Night mirror. Repair kits for damaged mirrors are available and most auto parts stores. The most important part of the repair is the beginning. Mark the outside of the windshield to locate the pad, then scrape the old adhesive off with a razor blade. Clean the remaining adhesive off with chlorine-based window cleaner (not petroleum-based solvent) as thoroughly as possible. Follow the manufacturers instructions exactly to complete the repair. Seats HOW TO USE THIS BOOK Inside Rear View Mirror 1131
REMOVAL & INSTALLATION Bench Seat Ranger bench seatClick to enlarge On the right side, remove the seat track insulator. 1. Remove 4 seat track-to-floor retaining screws (2 each side) and lift the seat and track assembly from vehicle. 2. To remove the tracks from the seat, place the seat upside-down on a clean bench. 3. Disconnect the track latch tie rod assembly from latch lever and hook in the center of the cushion assembly. 4. Remove 4 track-to-seat cushion retaining screws (2 each side) and remove the tracks from the cushion assembly. 5. To install: Position the track to the cushion assembly. Install the 4 track-to-seat retaining screws and tighten. 6. Connect the track latch tie rod assembly to the latch lever and hook in center of cushion. 7. Position the seat and track assembly in the vehicle. 8. Install the 4 seat track-to-floor retaining screws and tighten to specification. 9. On the right side, install the seat track insulator. 10. Bucket and 60/40 Seats HOW TO USE THIS BOOK 1132 REMOVAL & INSTALLATION
Ranger bucket seat Click to enlarge Explorer/Mountaineer bucket seat HOW TO USE THIS BOOK REMOVAL & INSTALLATION 1133