Body - Front Window(s) Pop/Thump Noise at End of Travel

Article No.
04-5-7

03/22/04

BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT
END OF WINDOW TRAVEL AND/OR DRIVER'S
WINDOW BOUNCE BACK AND REVERSE TO
MID-POSITION

FORD:
1997-2003 F-150
1997-2004 EXPEDITION

LINCOLN:
1998-2004 NAVIGATOR

ISSUE

Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating.

ACTION

To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below.

SERVICE PROCEDURE

1. Remove inner door panel, refer to Workshop Manual Section 501-11.

2. Remove exterior mirror, refer to Workshop Manual Section 501-09.

3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft).

4. Lower door glass to position it out of the way.

5. Remove inner and outer belt molding.

6. Position aside front window run.

a. Remove retainer.

b. Position outside of work area.








7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2).

NOTE
TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE.

8. Reposition front window run.

a. Install retainer.

b. Torque retainer to 11 N.m (8 lb-ft).

9. Install inner and outer belt molding.

10. Install exterior mirror, refer to Workshop Manual Section 501-09.

11. Install inner door panel, refer to Workshop Manual Section 501-11.

12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11.





Parts Block

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

DEALER CODING
CONDITION
BASIC PART NO. CODE
7820125 42





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