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.
Lower window by pushing it or through access plate.
Open tailgate.
Remove access panel (if not done in step 1), access panel
support, and water shield (paper).
Move window to 1/2 open position.
Remove 4 nuts (2 on each side) that connect the glass bracket
to regulator assembly "C" channel.
Slide glass all the way out (cannot be removed due to glass
brackets).
Stack boxes or something to support glass.
Unplug wiring harness to motor.
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.
The motor and regulator assembly can now be slid towards the
driver's side and lifted out.
Remove 3 bolts and 1 screw (under large gear - align access
hole) holding motor to regulator assembly.
Remove motor and then gear cover plate from motor.
Remove center steel gear.
Remove white plastic gear and clean out all pieces of original
torque pins.
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.
Reassemble the plastic gear, metal gear and spacers with plenty
of grease. The old grease looked like wheel bearing grease.
Grease and install this assembly in the motor housing.
Reinstall gear cover plate, and motor to regulator
assembly.
Replace motor and regulator assembly in tailgate. Watch the
wiring harness, it is easily pinched.
Clean and regrease the channel before reattaching "C" channel
to glass bracket. This will make for smoother and quieter window
operation.
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
**** **** / SAN BERNARDINO, CA, UNITED STATES
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
chrisreid / evans, GA, UNITED STATES
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
Painmistress / Lindenhurst, NY, UNITED STATES
Posted Feb 02 2009 04:16PM
The article about Bronco Tailgate Window Mechanism Fix is all good,but my problem is the window is stuck in the down position and will not go up.The track I think broke.Is there any way to get the window to go up even just a little bit to fix it?
Ed McCloskey / Maple Shade, NJ, UNITED STATES
Posted Feb 10 2009 01:42PM
My rear windoe for a 1988 Eddie Bauer is stuck closed. Where can I find and electrical diagram? Thanks Ed
Phill L / Chico, CA, UNITED STATES
Posted Apr 08 2009 11:18PM
This article really helped me out! I had this problem and had no clue what was causing it... now I have the motor completely apart. It looks as if my center gear forced its way through the plastic gear, has anyone else seen this? It looks like there still may be enough plastic left for it to work with some new torque pins. -Phill
Phill L / Chico, UNITED STATES
Posted Apr 08 2009 11:22PM
This article really helped me out! I had this problem and had no clue what was causing it... now I have the motor completely apart. It looks as if my center gear forced its way through the plastic gear, has anyone else seen this? It looks like there still may be enough plastic left for it to work with some new torque pins. -Phill
Charles / Lakewood, WA, UNITED STATES
Posted Apr 11 2009 10:13PM
I have a 98 Ford Bronco and my problem is my rear window is stuck in the down position and will not go up.Ihave power going to the tail-gate window.Ican't get to the motor because the window is down
Charles / Lakewood, WA, UNITED STATES
Posted Apr 27 2009 08:12PM
I have a 1988 Ford Bronco and my problem is my rear window is stuck in the down postion and will not go up . I have power going to the tailgate. I can't get to the motor because the window is down
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.
Own your very own Off Road Superstore..... How many times have you pondered the idea of owning your very own off road shop? Let the staff at Off Road Innovations, one of the largest aftermarket off road accessory dealers in the US, help turn your hobby into a profitable career. Go to www.offroadinc.net for more info or just call 800-809-6088.
MSD Ignition Rebate! Fire up with MSD Ignition and receive Cash for Cruising! Click on the link to find out the latest cash back rebate from MSD.
Posted Sep 02 2007 03:14AM
