Bronco Tailgate Window Mechanism Fix - Trucks 4x4 @ Off-Road.com
Trucks & 4x4 »

Price and Compare Vehicles:
New, Used, and Powersports    Go button

Bronco Tailgate Window Mechanism Fix

ORC STAFF
Ford at Off.Road.com

A common problem for older Broncos is for the tailgate window lift mechanism to fail. This fix is for when the window stops moving but the motor still runs.
  1. Lower window by pushing it or through access plate.
  2. Open tailgate.
  3. Remove access panel (if not done in step 1), access panel support, and water shield (paper).
  4. Move window to 1/2 open position.
  5. Remove 4 nuts (2 on each side) that connect the glass bracket to regulator assembly "C" channel.
  6. Slide glass all the way out (cannot be removed due to glass brackets).
    • Stack boxes or something to support glass.
  7. Unplug wiring harness to motor.
  8. Remove 4 bolts (2 on each side) that hold motor and regulator assembly to tailgate.
    • If you have outside spare tire mount, the 3 mount latch retaining bolts must be loosened.
  9. The motor and regulator assembly can now be slid towards the driver's side and lifted out.
  10. Remove 3 bolts and 1 screw (under large gear - align access hole) holding motor to regulator assembly.
  11. Remove motor and then gear cover plate from motor.
  12. Remove center steel gear.
  13. Remove white plastic gear and clean out all pieces of original torque pins.
  14. Make 3 new spacers out of ~1/2" O.D. rubber tubing. This provides the cushion against sudden starts of the motor. Fill the interior of the tubing with solid rod of appropriate size. The rod gives rigidity to the spacers.
    • Other list members have said that replacement torque pins ($3 each) and well as rebuild kits ($15) are available from parts stores. Ford dealers sell the assembly for about $70. See 2 letters below for more info.
  15. Reassemble the plastic gear, metal gear and spacers with plenty of grease. The old grease looked like wheel bearing grease.
  16. Grease and install this assembly in the motor housing.
  17. Reinstall gear cover plate, and motor to regulator assembly.
  18. Replace motor and regulator assembly in tailgate. Watch the wiring harness, it is easily pinched.
  19. Clean and regrease the channel before reattaching "C" channel to glass bracket. This will make for smoother and quieter window operation.
  20. Before replacing access panel and support, don't forget to reattach the wiring harness. :-)
Note:
  • Window regulator assembly has a strong helper spring. If the regulator arms are not against the stops they could snap there at any time causing injury and damage. Be careful.
  • I cannot take credit for this fix, just the writing of it. The fix came from members of the Big Bronco Mail list.
  • It shouldn't matter, but this fix was performed on an '88 XLT.
Ray
Comments from readers:
Mike
I have a 1978 Bronco. I found that a power window motor and gear housing from a 1988 Lincoln Town Car rear car door will bolt in exactly into the tailgate.
I had a 1988 Town car I used for a demo derby, I kept the window motors. One day, my rear window motor puked on my bronco. I couldn't believe that a window motor from a CAR that was TEN years newer was the exact same thing.
The front window motor gear housings are slightly different, but the motors will bolt up to a gear housing that will work.

Robert
I disassembled an old ('78) Bronco rear window motor I have, and found that the little round drive pins were (unsurprisingly) powder. I also confirmed that the 4th generation ('88-'96) Corvette headlight motor bushings work here; they're Delrin, $4.99, P.N. 601-703 from Mid-America Designs in Effingham, Ill. (1-800-500-VETT)
The bronze gear that Mid-America has for Corvettes is a little different story: it is the correct gearing, width and diameter, but has a raised boss on one side that could easily be machined off by someone with access to a lathe - or even a mill. It's (going from memory now) approx. 0.100" too thick on one side only. Mid-America sells it with replacement bushings included (that are somewhat oversize) for $60, a little pricey I think, but having installed two in Corvettes, I know it functions flawlessly there, so the gear machining is good.
Overall, the 'Vette headlamp motor and Bronco rear window motors look near as dammit to being identical.
Comments from our Readers
 Posted Sep 02 2007 03:14AM
THANX FOR POSTING THIS FIX, THE ONLYPROBLEM I FACED WAS TRYING TO PUT THE PIECES OF HOSE IN PLACE AND AS THAT ALL THE STORES WERE CLOSED I OPTED, FINALLY TO USE THE HARD RUBBER FAUCET WASHERS IN IT'S STEAD. I STACKED THREE IN EACH SLOT AND USED A SMALL FLAT EDGE SCREW DRIVER TO PRESS THEM IN. I PLAN ON GETTING A REPAIR KIT WHEN I HAVE TO GO IN AGAIN. COULD YOU POST SOME PICS ON HOW YOU INSTALLED YOUR SOLUTION? AGAIN THANX
 Posted Nov 06 2007 06:08PM
my back window is so messed up i dont even know where to start none of my switches work for the back window and the motor is messed up
Read More Comments
post a comment
Your email address will NOT be published.
appears with your comment
read our privacy policy
Note: does not support HTML
All comments submitted are subject to review, and may be delayed before posting. We reserve the right not to post comments.
Untitled Document
Sponsored Links
Off-Road Videos -
Check out over ten years of extreme 4x4 action, product testing and the Off Road Nation at play. Baja racing to rock crawling, ATVs in the sand to motorcycles in the dirt, it's all here. Rate them, share them and upload your own.
ATV Reviews -
Honda, Suzuki, Yamaha, Polaris, Kawasaki, Can-Am. First rides to long-term tests, check out the latest in ATVs, UTVs and Side-by-Side vehicles of every make and model. Read expert opinions and follow custom project vehicles.

Enewsletters

Stay on Top of All the Action:
Sign up for Off-Road.com's Enewsletters

Source: Ford at Off.Road.com,
Click here