How to Rebuild/Reinstall Window Motors for sn95 w/pics
There are a lot of people that run into the problem of non-fuctioning windows. If you hear a buzz when you hit the switch but the window doesn't move then this how-to will help you fix the problem.
1. Start by removing the window and mirror control cup. Carefully lift it out of the door panel. Once out remove the switch connectors from the mirror and window controls. Window controls may need to be unscrewed but the mirror switch will just unplug.
2. Once the control cup is out of the way. Carefully remove the door handle cup. Do this by pushing the front of it out from the inside of the door panel. The cup will come out fairly easily.
3. Next, begin removing the door panel. You do not need to remove the Mach460 tweeter housing to do this. First remove the screws and plastic snaps holding the panel to the door. Push up and slightly forward to remove the panel. Remember do not force anything. Just work with it until it comes off.
4. Once the panel is off unhook the window motor connector and dislodge it from the door frame. Then unbolt the 3 bolts holding the motor in place with a 5/16 socket.
5. When the motor is unbolted reach forward into the door through the large hole. Grasp the window motor and gentle slide it down and work it out of the door.
6. With the motor out find a clean work area. Use a hammer and a flat head to pop the clamp on cover off. The will be two points that will need a tap. It should come off easily but may require slight prying.
7. With the cover off, clean as much of the broken bushing out as you can. I just turned it upside down and tapped it.
8. Now locate the pin holding the gear assembly in place. Push a flat head under one ring and above the other then twist it over the top of the shaft. BE CAREFUL IF THIS PIECE BREAKS OR FLIES OFF SOMEWHERE YOU'RE SCREWED!
9.Once this piece is off slide the rest of the assembly of the shaft and clean everything.
10. Regrease and put the bushings in place and reassemble. Bushings may need to be sanded down slightly but will eventually work themselves in.
11. Pop the cover back on with your hammer and put the motor back in the door.
12. Put the panel back on. Then the cups. If there is material sticking out of the top of your door gently run a flat head along it to push it out of sight.
Last pic I have shows how I mounted the bushings. I used a dab of grease to get them to stick in position. After about 10 min. of sanding on the bushings the assembly slid right into place.
i determined that my right window motor of my 94 GT has the bushing broken, because: the window does not goes up or down, when i press the switch the motor works but the window does not move, if i open the door and help the window pulling it up while i am pressing the up switch it goes up, the same happens if i push the window down while i am pressing the down switch.
next step was to buy the famous gears, i bough it at mustang unlimited see the link http://www.mustangsunlimited.com/ite...s&CatKey=74-01 (they clame this fit 71/09 mustangs and 69/73 cougar) when i took apart my motor realized that my old gear is bigger (62 spline, 11 tooth) than the new one that is 45 spline, 9 tooth, and the fact that the new one does not have the bushing or torque pins, instead it has 4 springs that complete the assembly.
so now i need help, and have some questions. 1. Does anybody know where can i find the 62 spline, 11 tooth gear for 94 mustangs? store and part number please. 2. Does the 45 spline, 9 tooth gear can fix mine my old gear (62 spline, 11 tooth) by changing the bushing from the new to the old gear, i mean the bushings or torque pins are interchangeable in the two gears? 3. where do i find the 45 spline, 9 tooth gear with the bushing design, and not the one i got witch does not have the bushings,
attached some pictures of the piece of crap gear that i received.
Your help is really appreciated, (since my door is still all apart) thank you very much
The gear itself does not need to be replaced. It is only the bushings that need replacement. You can pick up a set at autozone. Ask one of the employees to help you. Tell them it is a window motor repair kit or motor bushings. They are easy to find, they are just 3 round plastic donut looking things. They may not fit perfectly so it may be a good idea to pick up some sand paper to sand them down so they pop into place.
Flosshogg, I assume you mean that the bushings fit any gear you have (62 spline, 11 tooth. or 45 spline, 9 tooth).
Well, I live in Dominican Republic and there is no autozone here, so instead of order it in the web and have the chance to receive the wrong part again, I made the bushings myself.
I bought 3 inches of a 0.5" diameter Teflon cylinder, I cut it in 6 pieces (0.500” inches height each, and use sand paper to reduce its height and diameter until they fix into the gears… I used 3 and have three additional for spare.
After that I took the motor apart clean everything inside, clean the contact point of the carbons and the rotor with sand paper, grease everything up (Motor, gears and the door mechanism (I think it is called regulator)), installed it and now the window works like brand new.
PS. Next week I will have to do the same to my other door since now I noticed the difference between the one that I fix and the other one, the window in the one I fix is mush faster now.
How to Rebuild/Reinstall Window Motors for sn95 w/pics 
thank you very much 
