Door window swap

[Blank-Disk]

I'm going to attempt to swap out a window from my current crappy door (front passenger gen2), to a newer less crappy door with a crappy window. Are there any special tricks/cautions/advice you all might have?

 

[SHO--ripper]

If you have a door to practice on i'd do that.

 

[FuzzyFish]

If you can practice it like said above do it, if not here are the steps to do it. Ford used two rivets to hold the window in the process to get it out is some what of a pain. But thankfully not overly difficult, inorder to swap a window you will need the following:

-A steel punch (preferably with a flat tip)
-A short piece of 2x4 (2 to 4 inches long), or something to fit behind the track.
-A hammer
-A cold drink (or warm depending where you live)
-A nail or anything long and small in diameter
-A drill, and a large reasonably sharp bit
-2, bolts with nuts/large flat washer (don't remember the exact length off hand)
-A shop-vac

Then to do this:

1. Remove the door panel.
2. Carefully remove the sound deadening material
3. Remove the speaker out of the door
4. Remove the weather proofing plastic very slowly (Tears easily)
5. Raise/lower window until you have clear access to the rivet
6. If you have power windows TURN THE KEY OFF after moving it. It wouldn't be hard to accidently bump the window switch, and getting hurt is no fun and how much effort it takes to move that, I'd hate to see what it can do your hand.
7. Once you have clear access, place the short 2x4 between the track and outside of the door, but NOT behind the rivet. (You might need to hold it)
8. Now take the punch, and place it in the center of the rivet. And use the hammer to tap it out.
9. Once it is most of the way out take the nail (or other small pointy thing) and push the center of the rivet out the rest of the way.
10. Use the drill to remove the head of the rivet, make sure you don't go through the track it self. (The rivet is aluminum, the track is steel you'll know once you hit it)
11. Use the hammer & punch to remove the remains of the head.
12. Use the hammer & punch to push the rivet all the way through. (or the nail if the punch is too big)
13. Repeat above process from step 5 on the second rivet.
14. Pull window out through top carefully if you can have someone help you with this.

Now to replace the window:

1. Get a friend to help, it will make it much easier!
2. Push(fold it a bit, don't remove it) the weather striping back to get the window in
3. Lower the window until it lines up with one hole in the track. Raise/lower the track if necessary.
4. Take a bolt and washer, and insert it from behind
5. Put the washer on the other end and hand tighten the nut leave it a bit loose
6. Repeat steps 3 to 5 on the other mounting point.
7. Clean up any shavings/remains of rivets unless you feel like hearing rattling when driving
8. Raise, and lower the window make sure it's on the track, and that the bolts don't hit anything.
9. Tighten the nuts up a bit. (don't make it overly tight)
10. Cut off the end of the bolt if necessary.
11. WARNING: This is the most important step of all!!! Close the window, stand back about 5 to 10 feet. Take your cold/warm drink take a drink, and admire a job well done!

Hope this helps!

 

[morpho18]

I'd suggest taking pictures and submitting the above guide to SHOPP. Great write up!

 

[FuzzyFish]

Pictures yes, do it again for the 5th time no.