Tools you'll likely need:
* Panel removal tools: These are plastic pry tools designed to avoid scratching the panel. A trim removal tool set is ideal. Avoid metal screwdrivers.
* Phillips head screwdriver: Possibly needed for screws.
* Small flathead screwdriver (optional): May be helpful for prying stubborn clips.
* Towel or rag: To protect the door panel and your paint.
Procedure (General Steps):
1. Power Windows & Locks: Disconnect the negative battery terminal to prevent accidental electrical shorts. This is a crucial safety precaution.
2. Window Control: Fully roll down the window. This gives you better access.
3. Door Handle: Remove the door handle bezel. This usually involves carefully prying it away with your panel removal tools. There are typically small clips holding it in place. Look for screws before prying.
4. Armrest (if applicable): If your armrest is removable, remove it. This usually involves unscrewing it from the inside.
5. Interior Door Release Handle: Remove the interior door release handle. This often involves unscrewing it from the inside or popping off a cover.
6. Screws: Look for screws along the edges of the door panel. They're usually hidden under covers or small trim pieces. Remove them carefully.
7. Clips: The majority of the door panel will be held on by plastic clips. Starting at the bottom, carefully insert your panel removal tools into the gap between the door panel and the door. Gently pry the panel away, working your way around the perimeter. The clips can be brittle, so apply gentle, even pressure. Don't force anything. If you feel resistance, try a different area.
8. Wiring Connectors: Once most of the panel is loose, carefully disconnect any electrical connectors (for the window switch, door lock, etc.). These usually have a release tab that you need to press to disconnect them.
9. Remove the Panel: Carefully pull the door panel away from the door. Be mindful of any remaining clips.
Important Notes:
* Take your time: Rushing this process will almost certainly lead to broken clips.
* Document the process: Take photos or videos as you go, especially when removing clips and connectors. This will greatly assist in reassembly.
* Be gentle: Plastic clips are fragile. Use plastic pry tools to avoid scratching the panel and breaking the clips.
* Replace broken clips: If you break any clips, they can usually be replaced with new ones from an auto parts store.
Remember, this is a general guideline. A repair manual specific to your 1995 Ford Windstar GL will provide the most accurate and detailed instructions for removing the door panel. If you are not comfortable doing this yourself, it's best to take it to a professional.
