Question about 2004 Ford Freestar

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2004 Mercury Monterey left frnt window sector gear R&R proceedure

2004 ford freestar / 2004 mercury Monterey left front window regulator removal & repair. How do you actually accomplish this while the entire assembly is hidden and riveted! How is the regulator - sector gear secured to avoid the "PHYSICAL PERSONAL INJURY" warning included with the replacement part. Yikes!

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  • yadayada
    yadayada May 11, 2010

    perhaps u should go to the dealer.

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  • Ford Master
  • 4,369 Answers

Are you a techie? You need a heavy duty riveter to do this repair. May have to rent or borrow from auto store.

here's the procedure



Front Door Trim Panel 2004 Mercury Monterey left frnt window sector gear - s4w~us~en~file=adobe.gif~gen~ref.gif Printable View (251 KB) NOTE: LH side is shown. RH side is similar.

  1. Remove the parts in the order indicated in the following illustration and table.

    df2877a.gif

  2. Item Part Number Description 1 23942/23943 Mirror access panel 2 1722897 Cup assembly 3 W56904-S424 Window regulator control switch panel screws 4 14A665 Window regulator control switch panel
    Removal Note 5 W701930-S424 Front door trim panel screw 6 W701930-S424 Front door trim panel screw 7 N602703-S61 Front door trim panel screw 8 1723943 Front door trim panel 9 W705590-S300 Nut insert(s)
  1. To install, reverse the removal procedure.
Item 4: Window Regulator Control Switch Panel Removal Note
  1. If equipped, disconnect the electrical connector(s).
-----------------------------------------------------------------------------------
Door Window Glass — Front Special Tool(s) s4w~us~en~file=st1132a.gif~gen~ref.gif Heavy Duty Riveter
501-D011 (D80L-23200-A)
  1. Remove the front door trim panel. For additional information, refer to Section 501-01 .
  1. Position the watershield aside.
  1. Remove the parts in the order indicated in the following illustration and table.

    To remove individual parts, only carry out the lis2004 Mercury Monterey left frnt window sector gear - 4be8135.gif Part Steps Front door window glass 1, 3 Front door window regulator 1-5 Front door glass run 1, 3, 6-8
    4be8135.gif
Item Part Number Description 1 W706495-5100 Rivet (2 required)
Removal Note
Installation Note 2 N8621986 Nut (3 required) 3 21410 Front door window glass 4 W706495-5100 Rivet (4 required)
Removal Note
Installation Note 5 23200 Front door window regulator
Removal Note 6 N800507-S Bolt (2 required) 7 21596 Front door glass run 8 — Front door glass run (Part of 21596)
  1. To install, reverse the removal procedure.
Item 1: Rivet Removal Note
  1. Connect the window control switch.
  1. Connect the battery.
  2. Position the door window glass halfway down to gain access to the door window glass rivets.
    • Remove the rivets.
9391398.gif Item 4: Rivet Removal Removal Note Item 5: Front Door Window Regulator Removal Note
  1. Disconnect the electrical connector.
  1. s4w~us~en~file=ani_caut.gif~gen~ref.gif WARNING: Prior to power window motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. Failure to place the regulator arms in a fixed position can cause the spring to suddenly release resulting2004 Mercury Monterey left frnt window sector gear - b4c4793.gifl injury.
    NOTE: The counterbalance spring assists the window in the upward direction.
    Remove the bolts and the window regulator motor.
Item 4: Rivet Installation Note
  1. Using the special tool, install the rivets.
b4c4793.gif

Posted on Mar 03, 2009

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6ya6ya
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    tb8635a.gif
    Figure 1 - Article 06-18-13



    tb8636a.gif
    Figure 2 - Article 06-18-13

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    tb8637a.gif
    Figure 3 - Article 06-18-13



    tb8638a.gif
    Figure 4 - Article 06-18-13



    tb8639a.gif
    Figure 5 - Article 06-18-13



    tb8640a.gif
    Figure 6 - Article 06-18-13



    tb8641a.gif
    Figure 7 - Article 06-18-13

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