1. Preparation:
* Safety First: Wear safety glasses and gloves to protect yourself from broken glass.
* Gather Tools: You'll need a variety of tools, possibly including:
* Window removal tool (a specialized tool is best, but you might be able to improvise with plastic trim removal tools and a putty knife)
* Screwdrivers (Phillips and flathead, various sizes)
* Pliers
* Utility knife
* Panel removal tools
* Clean rags
* New window (get the correct type, including tint if needed)
* Window adhesive (urethane-based automotive window adhesive is crucial)
* Caulking gun
* Possibly a window regulator repair kit (if the regulator is damaged)
2. Door Panel Removal:
* Carefully remove the interior door panel. This usually involves removing screws, clips, and possibly disconnecting electrical connectors (power window switch, etc.). Refer to your repair manual for the exact procedure. Take pictures as you go to help with reassembly.
3. Window Removal:
* Assess the Regulator: Inspect the window regulator mechanism. If the window is stuck or the regulator is broken, you'll need to repair or replace it before installing the new window.
* Detach the Window: This is often the trickiest part. The window is likely held in place by a combination of the regulator and possibly some adhesive. Use your window removal tool to carefully pry the window free, working slowly around the perimeter. Be extremely cautious not to damage the regulator or the door.
4. Regulator Repair or Replacement (if necessary):
* If the regulator is broken, you'll need to replace it. This usually involves removing the regulator from the door and installing the new one. Again, your repair manual is invaluable here.
5. Window Installation:
* Clean Surfaces: Thoroughly clean the window channel and the new window to ensure proper adhesion.
* Apply Adhesive: Apply a bead of automotive-grade window adhesive to the channel, following the instructions on the adhesive packaging.
* Install Window: Carefully insert the new window into the channel, ensuring it's properly seated and aligned.
* Secure Window: Once the window is in place, gently press it firmly against the channel to ensure good adhesion.
* Allow Adhesive to Cure: Follow the adhesive manufacturer's instructions for curing time. This typically involves allowing the adhesive to cure for several hours or overnight.
6. Reassembly:
* Carefully reinstall the interior door panel, paying close attention to the proper placement of all screws, clips, and electrical connectors.
Important Considerations:
* Glass Safety: Broken glass is dangerous. Be meticulous in removing the old window and disposing of the fragments safely.
* Repair Manual: A repair manual is absolutely crucial for this job. It provides specific instructions, diagrams, and torque specifications necessary for a successful repair.
* Professional Help: If you're uncomfortable with any part of this process, consider taking your car to a professional auto glass repair shop. The cost of professional installation might be less than the cost of a damaged door if you make a mistake.
This is a simplified overview. Attempting this repair without a repair manual specific to your 1991 Lincoln Town Car is strongly discouraged. Incorrect procedures could lead to damage to your vehicle.
