Question about 1992 Ford Explorer

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I need to install the plastic gears in my 1992 ford explorer power windows.

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There are 3 plastic bushings inside the gear drive of the power window motor . Remove the 2 screws above the pull handle.Then pry out the face plate.Then pry off the door panel.Work your way around the sides and bottom.Remove the door panel by lifting up and away. Unscrew the switch and move the door panel out of the way.Remove the speaker screws.Remove the speaker and wiring.Remove the speaker housing.Peel back the dust shield.There are 3 bolts that have to be removed. There are access holes for 2 of them. The third hole has to be drilled with a 1/2 hole. There is a dimple where the 3rd hole needs to be drilled.Remove the bolts.Disconnect the wiring harness to the power window motor.And remove the motor. Will have to fiddle with the motor to get it out. Push it towards the outer door panel.You now have to remove the gear cover. Its the black part of the housing.This one was held in place with some screws. Remove the cover, and you'll see all the little bits and pieces of the old bushings.Remove the metal gears by lifting up. The front windows had a c-clip that had to be removed first.Remove the plastic gear by turning upside down and tapping. Clean up.Clean up the housing.Re-install the plastic gear.put some fresh grease on it. If you require exact step by step diagrams for this procedure.please click on the link below:-- ------------ Thanks. Keep updated for any more query. You can rate this solution and show your appreciation.

Posted on Jul 29, 2010


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My ford explorer window "both sides" withen 2 days

Yes they do use plastic in them. after time they wear out and cold weather will finish them off. You will have to replace the motor.

Nov 28, 2010 | 1998 Ford Explorer

1 Answer

Power windows will not work on '92 tempo

This is a common problem with Fords of this era. Most people mistakenly replace the motor which is expensive, but there are repair kits available that replace the gear unit in the motor mechanism.

One way to check to see if this is the problem is to open the door, sandwich the window glass with both hands and shove down. If it goes down then you need a kit. Or, if you press the window button and the motor makes noise but nothing happens, you need a kit.

Basically there is a large plastic gear that has 3 synthetic bumpers that hold a metal gear. These bumpers age and begin to deteriorate and eventually disintegrate. Sometimes the plastic gear strips out.

Search these part numbers for a picture or check out Napa or Autozone's website for an image.

Part # BK 6551128

Part #
RAY 4922277

These normally run 20 bucks or so.

If you don't have a repair manual and you plan on working on your own car, get one. Haynes is ok but the best is an actual Ford Shop manual is priceless. Ebay is the best place to get them. My cougar manual cost 25 dollars and I wouldn't sell it for 100. You need the manual so you can get the door panel off with out breaking it too much. The plastic is old enough to vote and you can't glue it back together. I also recommend getting an interior panel pry tool for the same reason. Preferably a metal one as you can use it for other purposes as well.

Back to the window...

Replacing the gear goes as follows:

Raise window and remove door panel.

Remove window motor.

Remove the 4 screws and pop off the rubber seal. Grease the new plastic gear and reassemble and reinstall everything.

If I remember correctly one of the screws on the motor is a torx.

Jun 03, 2010 | 1992 Ford Tempo

1 Answer

My windows dont roll down

gear on window motor is worn

Jan 24, 2010 | 1992 Ford Explorer

1 Answer

My driver side power window wont go back up. I can hear the clicking sounds what should i do?

probably broke the plastic gear in the area where the motor is mounted to the regulator,not sure if you can replace just the gear or if you have to get another window regulator

Jan 05, 2010 | 2001 Ford Explorer Sport

1 Answer

1992 Ford Explorer Sport. Outside door handle not

Door handle seems loose and not connected? Then the plastic clip broke inside the door. Take off the door panel, 3 screws, and door lock cap and plastic insert around inside door handle. pry around the bottom first, and go up, when you reach the top, pull up, please be carefull to not break any more plastic. you will see a squarish opening midway up the door toward the latch. reach in and pull a rod toward the opening. You see a broken piece of plastic on the tip? if so take it off and get the replacement part for it at an autoparts store, install the new one and your set. I have broke to many of these so i ended up bending the end of the rod and using a nut to hold it in.:]

Jun 20, 2009 | 1992 Ford Explorer

1 Answer

Wondering if I can put power windows and locks on this vehicle as it's not equiped with them.

Unfortunately no. The design on the interior of the doors is different and cannot accomodate the needs of the power window motor, track, glass, wiring etc.

May 05, 2009 | Ford Explorer Cars & Trucks

1 Answer


remove your window motor from door usually 3 bolts hold it on or 3 rivets. if its riveted you need to drill them out . once the motor is removed you will see a black back plate held on by one small screw. remove this and pull the plate off and you will see a gear, remove the gear and you should see pieces of plastic shreded up in the motor. clean it out go buy a plastic toilet bowl screwand use the smooth side of the screw cut doown to fit in the motor with the gear on top .. it will need three pieces in there. put the gear back in reassemble the motor and test it before you put it back on it should work fine for several years. cost of DIY maybe $3. its not hard to do. ford sells a rebuilt kit but they would rather sell you a now window motor

Mar 28, 2009 | 1992 Mercury Grand Marquis

1 Answer

1992 ford explorer manuel transmission getting it into gear

Try putting it in 2nd, then 1st, if that works, sounds like you clutch is bad or defective. 1st gear has no syncro to slow the gears down, 2nd, 3rd, 4th, 5th do.

Mar 28, 2009 | 1992 Ford Explorer

1 Answer

1992 Ford Explorer Power Windows Will Not Work

A fiarly common problem on cars of this age, and in most cases they all go pretty much at the same time.

The problem is the overrun clutch in the motor gearbox. You can buy remanufactured units for about $65 each. (Window Lift Gear Kit) Look them up on the net.

You have to pull out the old regulator by removing the back window track, pull out the window, and then remove all the bolts and drill out the rivets holding the unit in place. You will need to drive out the center of the rivets using a punch, and then drill through them with about 1/4" drill.

(It's a lot easier and cleaner to cut around the old vapour barrier, (plastic sheeting), and then tape it back into place afterwards than it is to try to peel it off).

Hold the regulator in a vice to prevent the spring unwinding suddenly. Remove the motor/gearbox assembly from the regulator. remove the gearbox cover and clean out the bits of the old clutch. Spend the time to get all the bits out of the motor worm drive, but don't be tempted to remove the motor from the housting unless you are confident that you can reassemble the mortor brushes, (not easy). It helps to use a spray of WD40 or some solvent with a long nozzle to wash out the old grease and bits from behind the worm drive shaft.

Install the new gear kit and use plenty of grease supplied in the kit. Re install the regulator using 10mm or 1/4" nuts, bolts and washers in place of the old rivets.

Sep 13, 2008 | 1992 Ford Explorer

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