Tailgate Power Window - Glass Removal
84ford7Article No. 84-19-16
TAILGATE POWER WINDOW - GLASS REMOVAL
LIGHT TRUCKS 1983-84 BRONCO
When the power motor is inoperative with glass in full down positions, technicians cannot remove tailgate glass from vehicle as described in Shop Manual instructions because the tailgate torsion bar and rubber down stops preclude rocking glass off glass bracket retaining studs as described in Shop Manual instructions (Part 42-35-2).
Figure 32:
FIGURE 33:
FIGURE 34:
The following procedure is to be used for tailgate glass removal when the power motor is inoperative and tailgate glass is in full down position. Refer to Figures 32, 33 and 34.
Removal
1. Open tailgate in gate position.
Figure 32:
2. Remove inside cover access panel (10 screws) (Figure 32, View 1).
3. Remove inside cover water shield.
4. Remove inside cover panel support (1 screw) (Figure 32, View 1).
Figure 32:
FIGURE 34:
FIGURE 36A:
FIGURE 36B:
5. Cut templates from template sheet (See Figures 34 and 36 in the center of this Technical Service Bulletin) and position template for center punching holes on tailgate inner panel (Figure 32, View 2).
NOTE: Prior to center punching holes, the technician can eyeball center punch with glass bracket retainer nuts to assure hole location is directly aligned.
6. Cover glass with protective cover prior to drilling (4) holes in tailgate inner panel.
FIGURE 33:
7. Using a 5/8" diameter hole saw, drill (4) holes in tailgate inner panel at four template hole locations (Figure 33, Views 3 and 3A).
8. Clean drillings from area.
9. Using each drilled access hole, remove the (4) glass bracket retainer nuts.
10. Using undersize 5/16" drill punch, remove glass bracket "C" channel from glass and glass bracket to separate tailgate glass (Figure 33, View 4).
11. Remove protective cover and drillings.
FIGURE 34:
12. Reaching through tailgate panel access holes, grasp glass bottom edge cutouts and slide glass to half open position (Figure 34, View 5).
FIGURE 34:
13. If tailgate has heated glass option, disconnect two terminals (driver side) (Figure 34, View 6).
14. Pull glass to full open position and support glass (Figure 34, View 5).
15. Disconnect motor wiring harness.
16. Remove power motor attaching screws (4).
17. Reinstall new power motor.
18. Install glass bracket "C" channels onto the regulator arm slide guides (Figure 34, View 7).
19. Position tailgate glass over glass bracket "C" channel studs and install (4) screw and nut retainers (6-11 ft.lbs. torque) (Figure 34, View 7).
20. Lower glass to connect heated glass wiring terminals.
21. Close tailgate and cycle glass to assure smooth operation.
22. Open tailgate and apply body color touch up paint to drilled hole surfaces.
23. Install inside cover panel support (1 screw).
24. Install water shield.
25. Install inside cover access panel (10) screws.
26. Install (4) 5/8" diameter rubber plugs (376966-S) in drilled holes.
27. Close door and cycle tailgate to assure proper function.
PART NUMBER PART NAME CLASS
376966-S Rubber Plug S
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP23394A84
TIME: .7 Hr. DLR. CODING: Basic Part No. 7023394 Code: 46