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Old 04-25-2005, 13:01   #1 (permalink)
Bill Jeffrey
Posts: n/a
'02 XLT electric window mechanism repair

Good morning, all -

I have an '02 Explorer 4-dr XLT. A year ago we were rear-ended by a
lightweight Hyundai. The damage (to us, not the Hyundai!) was pretty
well confined to the trailer hitch and rear bumper, and was easily
repaired by a body shop. However, at the same time, the operation of
the left rear-seat electric window became intermittent, and finally it
stopped going up and down at all. This MAY be coincidence - there was
no damage anywhere near the door.

I have removed the trim panels from the door to get access to everything
inside it. I have confirmed that electric power reaches the motor when
any of the switches are operated, and that the polarity of the power
reverses for DOWN vs UP. I opened the connector in the door that goes
to the motor, and used my ohmmeter to measure the resistance of the
motor (I am an EE). It tells me that the motor resistance is about 1
ohm (which is about right for a motor), and it also confirms that the
circuit breaker in series with the motor is OK.

When I hit a DOWN or UP switch, I can hear the motor click as if it is
trying to start. But nothing moves, and the motor does NOT hum as if it
were spinning freely. So I conclude that something in the gearcase is
jammed. If it is like the mechanism that raises and lowers an electric
antenna, there is a nylon gear in there, and a gear tooth may have
broken off - but who knows?

First question - is this a reasonable conclusion? Does anyone know how
to check it, or to rotate the gear a bit by hand, to see if it kicks out
the obstruction and frees up?

Second question - I think I am faced with replacing the motor/gearcase
assembly - is this what is called the "regulator"? Or does the
"regulator" include the slides and tracks and the two rotating cables
that actually activate the up/down mechanism? Anyway, the initial
hurdle is that it seems that I must disconnect the hardware from the
glass, and it appears that the window must be DOWN in order to do this.
However, the window is stuck in the UP position, and since nothing
will move - well, you get the idea.

Any thoughts, ideas, or experience, are welcome. FWIW, I have a kind of
crappy CD of Ford Truck Workshop Information, but it is only partially



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