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Caravan, Grand Voyager, Town and Country, Voyager,
2000-2004
Blower Motor - Removal & Installation
Disconnect and isolate the negative battery cable, then wait 2
minutes before proceeding with the removal. This will effectively
disable the air bag system preventing possible personal injury.
Remove the glove box from the instrument panel.
Fig. The blower motor is located behind the glovebox, behind the
blower motor cover
Remove the A/C-heater blower motor cover.
Disconnect the blower motor wiring connector.
Remove the blower motor wiring grommet and feed the wiring through
the blower motor housing.
Remove the blower motor mounting screws.
Fig. Once the cover is removed, unplug the electrical connector
and push it through the opening in the housing
Fig. The blower motor is secured to the housing with three small
screws
Allow the blower motor assembly to drop downward to clear the
instrument panel and remove from vehicle.
To install:
Place the blower motor assembly into position on the A/C-heater
unit and tighten the mounting screws.
Route the blower motor wiring through the blower motor housing and
seat the wiring grommet in the hole of the blower motor housing.
Reconnect the blower motor electrical connector.
Install the A/C-heater blower motor cover.
Install the glove box into the instrument panel.
Reconnect the negative battery cable. Check blower motor
operation.
Auxiliary Heater and Air Conditioner Blower Motor -
Removal & Installation
Disconnect and isolate the negative battery cable.
Remove the right quarter trim panel as follows:
Remove first rear seat. Remove the second rear seat, if equipped.
Remove the sliding door sill plate.
Remove the quarter trim bolster.
Remove the upper C-pillar trim and D-pillar trim panel.
Remove the first and second rear seat belt anchors.
Remove the screws securing the quarter trim to quarter panel from
the bolster area.
Remove the screws securing the rear edge of the quarter trim to
the support bracket.
Carefully disengage the hidden clips securing the front of the
quarter trim to the quarter panel just rearward of the sliding door
opening.
Fig. Removing the trim panel to access the rear blower motor
Disconnect the wiring harness connector from the accessory power
outlet, if equipped.
On long wheelbase wagons only, remove the quarter trim from the
quarter panel and pull second rear seat belt through access hole.
Pull first rear seat belt through the access hole.
Remove the quarter trim panel from the vehicle.
Remove the 5 screws mounting the A/C-heater blower motor housing
to the rear HVAC unit (one mounting screw located on evaporator cover).
Twist the blower motor out of scroll housing.
Disconnect the blower motor wiring connector.
Remove the blower motor from vehicle.
Fig. The rear blower motor is held in place by four screws
To install:
Install the blower motor unit into the vehicle.
Reconnect the blower motor wiring connector.
Secure the blower motor into scroll housing.
Install and tighten the 5 screws mounting the A/C-heater blower
motor housing to the rear HVAC unit (one mounting screw located on
evaporator cover).
Install the right quarter trim panel as follows:
Install the quarter trim panel in position in the vehicle.
Insert and pull the first rear seat belt through the access hole
in quarter trim panel.
On long wheelbase wagons only, insert and pull the second rear
seat belt through access hole in quarter trim panel.
Reconnect the wiring harness connector to the accessory power
outlet, if equipped.
Engage the hidden clips to secure the front of quarter trim to
quarter panel rearward of sliding door opening.
Install the retaining screws that secure the rear edge of quarter
trim to support bracket.
Install the retaining screws that secure the quarter trim to the
quarter panel in bolster area.
Install the second rear seat belt anchor (if equipped), and the
first rear seat belt anchor.
Install the D-pillar trim panel and upper C-pillar trim.
Install the quarter trim bolster.
Install the sliding door sill plate.
Install the second rear seat, if equipped, and install the first
rear seat.
Reconnect the negative battery cable. Check blower motor
operation.
You have to remove the rear seat, then the metal side panel to access the window mechanism. Once you are there you will see some rollers that are probably broken. Any mustang shop will stock these, I like mustangsunlimited.com or NPD.com Good luck!
Locate the retainers securing the seat bottom into the vehicle, approximately 10 inches from the end of the cushion, either side. Use your thumb to push in retainer release tab. Lift the seat up to remove.
Remove the two 13mm screws securing the seat back, located on each lower corner. Lift seat upward to release seat back from brackets at the top. You can carefully prop the seat back under the retracted top , use caution if choosing this method not to damage or scratch the vinyl of the seat. You can remove the seat from the vehicle completely by disengaging the flanges securing the top of the rear seat to the fabric of the convertible top well .
Remove Quarter Trim Panels:
Grip the Quarter Trim Panel Cap at the shoulder strap opening and lift up to dislodge the retaining clips.
The inside Quarter Trim Panels are two-piece panels. Remove the upper portion of the Quarter Trim Panel from the vehicle; it is not necessary to remove the lower portion. Pull the forward edge of the trim Panel over the pinch weld in the doorjamb.
Use a Door Trim Tool (Fork Tool) to dislodge the pushpin retainer at the rear edge of the Trim Panel approximately 4” down from the top, pry Trim Panel toward the outside of car to release retainer.
NO. there will be 4 bolts under each seat, pull the seat all the way forward and remove the rear 2 bolts at each end of the seat track, then push the seat all the way back and remove the 2 front bolts.
Retractor and Tongue—Sedan
SPECIAL SERVICE TOOL(S) REQUIRED
Description
Tool Number
Safety Belt Bolt Bit
T77L-2100A NOTE: Safety Belt Bolt Bit T77L-2100-A should be used for safety belt removal and installation.
Removal
Remove rear seat cushion. Refer to Section 01-10 .
Seat Cushion, Rear
Sedan Removal
Apply knee pressure to lower front portion of the rear seat cushion. Push rearward to disengage rear seat cushion pad and frame (600A88) from rear seat cushion front retainers (63370).
Remove rear seat cushion from vehicle.
Remove rear seat back. Refer to Section 01-10 .
Seat Back, Rear
60/40 Split Bench—Sedan Removal
NOTE: Safety belt bolts do not secure seat back to vehicle.
Remove rear seat cushion as described.
Fold down back seat and remove two bolts in the center of each seat back striker plates.
Remove two bolts from outboard rear seat back frame retaining brackets.
Lift seat back up and pull forward to remove from vehicle.
Remove panel (52018) and quarter trim panel (31012). Refer to Section 01-05 .
Trim Panel, Quarter—Sedan
Removal
Remove rear seat. Refer to Section 01-10 .
Pull up on rear section of rear door scuff plate that overlaps lower quarter trim panel.
Pull lower quarter trim panel away from body.
Remove safety belt retaining bolt.
Feed safety belt through lower quarter trim panel.
Remove safety belt anchor plate-to-sill bolt from quarter panel.
Remove retractor anchor nut and retractor from rear quarter panel.
Remove upper seat belt anchor bolt and anchor from upper rear quarter panel.
Slide anchor plate end of safety belt through the openings in the quarter trim panel.
Remove outboard front safety belt retractor and tongue (611B08) from the vehicle.
Item
Part Number
Description
1
386277-S190
Bolt (Part of 611B68)
2
31012
Upper Rear Quarter Trim Panel
3
611B60
Retractor and Tongue
4
N800937-S190
Nut
5
389370-S190
Bolt
6
—
Rear Quarter Panel (Part of Body)
7
52018
Lower Rear Quarter Trim Panel
8
—
Mounting Stud (Part of Body)
Remove seat belt anchor bolt and retractor and tongue from rear deck panel.
Installation
To install, reverse Removal procedure.
Make sure the safety belt webbing is not twisted. If it is, remove the twist.
Tighten retractor anchor bolt and safety belt anchor plate-to-sill bolt to 34-46 Nm (25-33 lb-ft).
Disconnect the speedometer cable from the speedometer head.
Remove the six screws retaining the instrument cluster assembly to the instrument panel and tilt the cluster forward.
Disconnect the wiring and the bulb sockets and remove the cluster assembly.
NOTE: All individual instruments may be removed and serviced at this time. To install:
Position the cluster and connect the wiring and bulb sockets.
Install the instrument cluster assembly to the instrument panel with the six retaining screws.
Connect the speedometer cable and the battery cable.
Check the operation of all gauges, lights, and signals.
I've done this many times
You will need a tubing cutter
Screwdriver
I think a 7 or 8mm socket
hose clamps
the appropriate amount of heater hose
zip ties
cut the steel heater line at the front in a place you can get access to,leave yourself enough steel hose on the rear to allow you to put the heater hose on cut off the steel hose and discard, and use 2 hose clamps on either end do the same for the other heater hose,this way is cheap and easy and permanant.Be sure that when you run the heater hose keep it away from hot or moving parts,use the zip ties to fasten it along the way,this should take about a half hour or so depending on your skills and working conditions,remember to buy some antifreeze to top up the system because you are going to spill some,remember to clean any spills animals love it and it is deadly.
only sounds after engine starts
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