Tools You'll Likely Need:
* Replacement window: Get the exact correct window for your Aerostar. Incorrect dimensions or type could cause problems.
* Window regulator: If the regulator is damaged, you'll need a replacement. Often, they fail around the same time as the window breaks.
* Panel removal tools: These may include trim removal tools, putty knives (plastic or metal, be careful!), and screwdrivers (Phillips and flathead).
* Socket set and wrenches: Sizes will depend on your Aerostar, so consult a repair manual.
* New window felts/seals (optional but recommended): These prevent leaks and rattling.
* Adhesive (if needed): Some windows use adhesive, and you'll need the appropriate type. Consult a parts store.
* Safety glasses and gloves: Protect yourself from broken glass.
Steps (General - Consult Your Repair Manual for Specifics):
1. Disconnect the battery: This prevents accidental shorts.
2. Interior Door Panel Removal: Carefully remove the interior door panel. This usually involves removing screws, clips, and possibly disconnecting electrical connectors for the window switch and other components. Take pictures as you go to help with reassembly.
3. Window Regulator Assessment: Inspect the window regulator mechanism. If it's damaged or doesn't operate smoothly, you'll need a replacement. This is a common issue with older vehicles.
4. Window Removal (If possible): If the window is still mostly intact and in the track, carefully lower it as much as possible. Then, you might be able to carefully remove the broken window remnants from the regulator mechanism.
5. Regulator Replacement (if needed): If replacing the regulator, carefully disconnect the motor and any linkages. Install the new regulator following the reverse order of disassembly.
6. Window Installation: Carefully install the new window into the regulator. Make sure it's seated correctly in the channels and glides smoothly.
7. Reinstallation: Reinstall the window regulator, carefully guiding the window into its track.
8. Interior Panel Reinstallation: Put the door panel back on, making sure all screws and clips are properly secured. Reconnect electrical connectors.
9. Testing: Test the window operation. It should move smoothly up and down.
10. Exterior Seal (If necessary): If the old seal is damaged, replace it. This step is crucial to prevent water leaks.
Important Considerations:
* Repair Manual: A Haynes or Chilton repair manual specific to your 1989 Ford Aerostar is invaluable. It will provide detailed diagrams and instructions, saving you time and frustration.
* Glass Disposal: Dispose of the broken glass properly. Wrap it securely and take it to a recycling center.
* Professional Help: If you are not comfortable with automotive repairs, consider taking your Aerostar to a qualified mechanic. Improperly installed windows can lead to safety hazards.
This is a simplified overview. The actual process might be more intricate depending on your specific Aerostar model and the condition of the existing components. Always consult a repair manual for detailed, model-specific instructions before attempting this repair. Safety first!
