Remove the motor housing only instead of the whole system. This does not take as long and it is easier to repair the most common broken part. Help #74410 gets you the nylon power window regulator gear plugs. At $6.00 it's a deal and you won't have to replace the original motor (if it's still making noise). For Canadians I got it at AutoParts Extra. Many jobbers stock the "Help" line though.

Tools You Will Need

1 ¾” cap screw (part OEM-723-3018) #2 Phillips screwdriver Power drill and 1/2" drill bit (or 3/4" hole bit) Robertson screwdriver (#3) — Fits No. 12 and larger screws) 4) Help products #74410 Window Regulator Gear Plugs for Ford White permanent marker Small standard screwdriver (to remove the center gear) Motorcycle chain lube (or WD40) Synthetic grease (for the top gear)

Let's Get Started

Pop the door pull handle trim covers off with a "right small" screwdriver and stash em' where you won't step on them.


After this 3rd screw and the 4th one on the inner side are removed you just pull from the bottom and off comes the door panel.


There was NO WAY I was drilling out all those rivets and removing the entire lift framework only to have to re-string the cables and bolt in all the framework again. I just drilled three half inch holes to expose the Robertson head motor retaining bolts.


After the three bolts are out and you've unplugged the motor, just pull the motor out far enough to get at it. This way you don't have to disturb, remove or adjust the cables at all.


The motor just pulls separate of the cable gearbox, which I did not want to mess with anyway
.

Now you and the motor can head to the bench, leaving the cable gearbox ALONE and untouched. You're not going to believe how cheap, easy and fast this is to do! Out comes one Phillips screw.



Everything looks normal so far. Just to be safe I index marked the gear with the case, to help reassembly.


In case anything moves I'll have a reference point to go by. With the center gear off (behind motor housing on bench) you can see those little nylon gear plugs have been crushed alright.


The new ones are at the rear of the photo opposed to the crushed originals closer to you.


Here's a shot of the empty gear casing. I pre-sprayed the housing with motorcycle chain lube before dropping in the new nylon gear plugs.


That's all there really is to the gearbox insides. Not really a bad system especially considering how cheap, fast and easy the plugs are to change. After slapping plenty of synthetic grease onto the top gear, It's pushed back on the shaft indexed to those earlier marks.




Put the cover and one screw back on and bolt it back onto the cable gearbox through the new holes in the inner door and you're ready for another 15 years service!