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TC POWER WINDOW MOTOR GEAR INSTALL
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If your power window doesn't move up or down but you can hear the motor turning, this tutorial is for you. The gear system inside the motor is made of plastic. The plastic parts tend to disinegrate over the years. This write-up details the rebuilding of the gear section of the power window motor on '83-'86 Turbo Coupes. I assume it's the same for other Fox bodied cars of the same era but don't know for sure.
This rebuild was performed on the passenger side of my '86 TC.
The first thing to do is disconnect the battery. Then remove the door panel. I've removed many a door panel in my day but this was more difficult than most. Many hidden clips and screws. TIP - the padded portion of the armrest is simply clipped in. Place a wide blade screwdriver between the material and plastic and GENTLY pry upwards. Also, when removing the door panel itself, it pays big dividends to have the proper door panel removal tool.
HarborFreight carries one for about $5. It's not so much the pushpins, it's the cardboard portion of the door panel that rips. And that can't be fixed! Take your time on the removal. Once the door panel and all insulation is removed, remove the speaker. You'll be able to see the motor at the bottom of the door. There are 3 small bolts in a triangular fashion holding it in. 7mm? You're going to have to drill 3 holes to access these bolts. Some TC's have dimples in the doors where you need to drill. Mine didn't.
Use a drill bit just a hair larger than the outside diameter of the 1/4" drive socket that you'll use to remove the bolts. If you don't have dimples, line the bit up as best you can with the bolts and have at it. The bottom hole will be below the door panel and will show. Not to worry! You'll plug that hole with a body plug when you're finished. Once the holes are drilled, remove the 3 bolts using a 1/4" drive socket, 6" extension and ratchet. Don't forget to unplug the electrical connection! Remove the motor and follow along with the pictures below.
Here's the motor removed from the door. Remove the outer cover.
Gently pry up the steel gear with a screwdriver. Once it's removed, gently pry up the plastic gear. Between the old grease and years of use, they're gonna be on there pretty good. Just work them off the shaft, gently.
Here's the 2 gears removed. Clean the old grease out of the case really well. Along with the grease will come chunks of plastic from the old torque bushings. That's the reason your window doesn't work anymore! Might as well clean the whole unit since it's out. Mine had some surface rust on the motor casing so I hit it with some black spray paint. The next photo is the new gear and torque bushings. The new gear is slightly different from the original but will work just fine. I bought this kit off of Ebay for $15. Search under Ebay seller 'partzway'. He sells alot of them.
Install 2 of the torque bushings into the new plastic gear and set the steel gear in place. Make sure the steel gear is cocked at an angle because you're going to have to wedge the 3rd torque bushing into place.
Now comes the fun part! Insert the 3rd torque bushing into place between the steel gear and the plastic gear. There's about an 1/8" of overlap and it definitely takes some finesse to work it in there! Take your time, work diligently and you'll eventually get it! Once you get that 3rd bushing started, push it down all the way and then gently tap the steel gear as far down as it will go. Note that it doesn't quite seat against the tops of the torque bushings.
Now apply a liberal amount of general all-purpose grease to the plastic gear and the shaft. Put a small amount on the steel gear then slip the whole assemble over the shaft until it seats.
Reattach the cover and you've just rebuilt your power window motor gear assembly! Reinstall the motor into the door (don't forget to hook up the electrical connection and the speaker wires) and button it all back up. Go to auto parts or any good automotive paint supply house and get a 7/16" rubber/plastic plug (it looks like a little top hat) to fill that one hole you drilled below the door panel. Reconnect your battery (set the clock) and test the window to make sure it works. You're good to go! Hope this helps.
