1. Diagnosis:
* Identify the problem: Is the window completely inoperable, slow, making grinding noises, or binding? This helps determine the extent of the damage. Common issues include broken cables, worn gears, or a faulty motor.
* Test the motor: Disconnect the electrical connector from the motor. Using a multimeter (or a 12V test light), check for power at the connector when the switch is activated. If there's no power, the problem might lie in the switch, wiring, or a blown fuse. If power is present, the problem is likely within the regulator mechanism itself.
2. Tools and Materials:
* Socket set and wrenches: You'll need various sizes to remove the door panel and regulator.
* Screwdrivers (Phillips and flathead): For removing interior trim panels and screws.
* Pliers: For working with the regulator cables and potentially other small parts.
* Needle-nose pliers: Helpful for manipulating small parts within the regulator.
* Replacement parts: This is the crucial part. You might need a new cable, gear, regulator motor, or even the entire regulator assembly. Get these from a reputable auto parts store, specifying your Expedition's year and trim level to ensure compatibility. It's often easier to replace the whole regulator.
* Shop manual (highly recommended): A repair manual specific to your 2003 Ford Expedition will provide detailed diagrams and instructions. You can often find these online in PDF format or purchase a physical copy.
* Interior panel removal tools: These tools prevent damage to your door panel clips.
3. Repair Procedure (General Steps; Refer to your repair manual for specifics):
* Remove the interior door panel: This involves removing screws, clips, and possibly disconnecting electrical connectors for the window switch, power locks, and speakers. Be careful not to break any clips.
* Disconnect the window motor: Unplug the electrical connector from the motor.
* Remove the window regulator: This usually involves removing screws and bolts that secure the regulator to the door.
* Inspect the regulator: Carefully examine the cables, gears, and motor for damage. If a cable is broken, you'll need to replace it. Worn gears might also need replacing. A faulty motor would require a motor replacement.
* Repair or replace the damaged parts: This is where you’ll replace the broken components. Repairing a broken cable can be tricky and requires specific tools and techniques. Often, replacing the whole assembly is more straightforward.
* Reassemble the regulator: Carefully reinstall all the components in the reverse order of disassembly. Ensure the cables are properly routed and tensioned.
* Reinstall the window motor and door panel: Reconnect the electrical connector to the motor and carefully reinstall the door panel, ensuring all clips and screws are securely in place.
4. Test the Repair:
* Test the window: Operate the window switch to check if the window moves smoothly and without any grinding noises. If there are still issues, carefully re-examine your work.
Important Considerations:
* Safety first: Disconnect the negative battery terminal before starting any work to prevent electrical shock.
* Patience is key: This repair can be time-consuming and requires attention to detail. Take your time and refer to your repair manual frequently.
* Professional help: If you're uncomfortable with any of these steps, it's best to take your Expedition to a qualified mechanic. The cost of professional repair might be less than the cost of replacing a damaged door panel due to improper disassembly.
Replacing the entire window regulator assembly is often the most practical and efficient solution. Unless you are comfortable with detailed mechanical repair and have access to the right tools and parts, this is the recommended approach. The cost of parts is typically far less than labor if you get a mechanic to do the entire job.
