Front Door Glass - Binds During Downward Travel
Article No.94-24-9
11/28/94
GLASS - FRONT DOOR - TIPPING AND BINDING DURING DOWNWARD TRAVEL
LIGHT TRUCK:
1986-94 AEROSTAR
This TSB is being republished in its entirety to include the 1994 model year and to include the latest level parts.
ISSUE:
The front "nose" of the door glass may tip forward as the glass starts its downward travel. As the glass rotates in the track, the nose and the lower rear corner start to bind in the base of the channels. The concern usually occurs within the first 2" (50.8 mm) of downward travel, and the severity increases with time as the flock in the base of the glass channel is worn through to the rubber.
ACTION:
Replace the worn channel glass run and remove lower attachment clip from door frame moulding. Also correct any tight condition in the channel area to allow smooth operation. Refer to the following procedure for service details.
NOTE:
MOTOR DRIVE REPLACEMENT ON POWER WINDOWS WILL NOT REPAIR THIS CONDITION.
REPAIR PROCEDURE
1. Remove door trim panel and watershield.
2. With glass in full up position, check retainer assembly for excessive wear in the base of the channel, Figure 1. Replace if worn and position as far upward as attachment slot will allow to attach Item "C," screw and washer assembly, Figure 1.
3. Cycle glass to check for binding. If binding persists, continue to Step 4. If there is no binding, proceed to Step 15.
4. Cycle glass to the full down position.
5. Remove flock run assembly.
6. Check flock run assembly at the forward leg, adjacent to the mirror, for excessive wear in the base of the flock run, Figure 1. Replace if worn (after Step 7).
7. Remove moulding (208A96) from door frame and remove lower "B" pillar clip. Reinstall moulding without lower clip, Figure 1.
8. Install flock run.
9. Cycle glass to check for binding. If binding persists, continue to Step 10. If no binding, proceed to Step 15.
10. Fabricate a tool from any convenient material such as aluminum, plexiglass, steel, etc., Figure 3. Quarter inch stock is recommended.
11. Starting at the upper rear corner of the door, insert tool into the glass run assembly. Make certain the tool has bottomed out in the channel by tapping tool handle with small hammer or mallet, Figure 2.
12. Remove tool from the glass channel by wiggling inward (toward passenger compartment) and outward (toward exterior of vehicle) as you pull the tool out until it releases from channel, Figure 2.
13. Repeat steps 11 and 12, working down the glass channel until binding is eliminated.
14. Check glass function: Cycle glass up and down several times to verify binding condition has been corrected.
15. Reinstall door trim panel.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 94-15-12
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Models
OPERATION DESCRIPTION TIME
942409AT Repair Both Doors 2.2 Hrs.
942409A Repair One Door 1.2 Hrs.
DEALER CODING
BASIC PART NO. CONDITION CODE
7021546 41
OASIS CODES: 102000