Body - Thump/Clunk Noise When Rolling Down Door Window
TSB 04-19-509/22/04
FRONT WINDOW CLUNK NOISE
FORD:
2004 Explorer
MERCURY:
2004 Mountaineer
ISSUE
Some 2004 Explorer/Mountaineer vehicles built 1/6/2004 through 5/15/2004, may exhibit a clunk noise from the window regulator when rolling down the front windows. In some cases the customer may experience a clunk/thump noise when positioning the window in the full down position only. This may be due to the rubber down stop bumper shearing off.
ACTION
Replace the window regulator down stop bumper.
Refer to the following Service Procedure.
SERVICE PROCEDURE
1. Remove the front door trim panel. Refer to Workshop Manual Section 501-01 for front door trim panel removal and installation procedures.
2. Peel back the water shield/weather insulator to expose access holes. Inspect for a broken/sheared rubber down stop bumper in the bottom of the door.
NOTE
IF THE DOWN STOP IS NOT DAMAGED CONTINUE WITH NORMAL DIAGNOSTICS, DO NOT REPLACE THE DOWN STOP BUMPER.
3. Reach through the rear access hole to the bottom of the window regulator rail/channel (Figure 1).
4. Install the replacement down stop bumper onto the window regulator rail/channel with the chamfer side down (Figure 2).
PARTS BLOCK
OPERATION/DESCRIPTION/TIME
WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7821762 42
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