Driver's Door Glass - Repeated Breakage

84ford16

Article No. 84-7-2

GLASS - DRIVER'S DOOR BREAKS - POLICE/FLEET


FORD 1982 LTD, 1983 CROWN VICTORIA

LINCOLN-MERCURY 1982 MARQUIS, 1983 GRAND MARQUIS

Dealers encountering repeat glass breakage on high usage fleet (Police) vehicles may use the following service procedure in place of prior information published in TSB 82-17, Article #1. (Refer to appropriate Car Shop Manual Parts 45 and 42.)

1. Remove door trim panel and watershield.
2. If TSB 82-17, Article #1 service has been made, remove the lower hinge bolt (389481-S2), support bracket (17263) and the nut and washer (45338-S2) from the vehicle as well as all broken glass.
3. Install (2) flat washers (5/16" - 7/8 x 7/64") on a (5/16" - 18 x 1-1/8") hex washer head screw (388346-S2) and install the screw into the front door lower hinge retainer hole.

NOTE: The screw (388346-S2) must not protrude beyond the door hinge tapping plate. (Torque the screw to 14-24 ft.lbs.)

FIGURE 2:

4. Fabricate a "bumper pad" made by applying a piece of E2AZ-6620552-A Body Insulator on top of a piece of D6AZ-5420552-A Body Insulator. Place the "bumper pad" onto the door sheet metal adjacent to the lower hinge tapping plate (Figure 2). This "bumper pad" will prevent the glass from contacting the door sheet metal when the door is overslammed with the glass in full down position.

5. Re-install door water shield and trim panel.
6. Cycle glass to full down position and close door several time to assure that the door glass does not contact door sheet metal upon closing. The "bumper pad" should protect the glass from making harsh sheet metal contact.

PART NUMBER PART NAME CLASS

E2AZ-6620552-A Body Sound Insulator CG
382623-S2 Screw Hex Washer Head SG


OTHER APPLICABLE ARTICLES: 82-17-1
WARRANTY STATUS: "INFORMATION ONLY"