1991 1999 ford explorer chilton User Manual

							
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