General Steps (Consult your repair manual for specifics):
1. Safety First: Disconnect the negative battery terminal to prevent electrical shorts. Wear safety glasses and gloves.
2. Access the Hinge: This is the most challenging part. You'll likely need to remove interior trim panels, possibly the rear side panels, and potentially parts of the rear cargo area to gain access to the hinge. The exact procedure varies greatly depending on whether it's the upper or lower hinge and the specific body style of your Explorer. Your repair manual will be essential here.
3. Remove the Old Hinge: This usually involves removing bolts, nuts, and possibly rivets securing the hinge to the vehicle body and the window itself. Take pictures as you disassemble to help with reassembly. Be extremely careful not to damage the surrounding bodywork. Some hinges might require specialized tools for removal (e.g., rivet removal tools).
4. Clean the Area: Thoroughly clean the mounting area of any rust, debris, or old sealant before installing the new hinge.
5. Install the New Hinge: Align the new hinge perfectly with the mounting holes. Use new bolts, nuts, and washers (if applicable). Tighten them to the manufacturer's specified torque (found in your repair manual). If rivets were used, you'll likely need to use new rivets and a rivet gun.
6. Reassemble: Carefully reassemble all the interior panels and trim pieces you removed in step 2. Make sure everything fits snugly and securely.
7. Test the Window: Reconnect the battery and test the rear window to ensure it operates smoothly and safely.
Important Considerations:
* Rust: On older vehicles like a 2002 Explorer, rust can significantly complicate this repair. Expect to encounter some rust and potentially need rust removal tools and treatments.
* Specialized Tools: You may need specialized tools beyond basic hand tools, such as rivet guns, torque wrenches, and possibly panel removal tools.
* Window Removal: In some cases, you may need to partially or completely remove the rear window to access and replace the hinge. This is a delicate process that requires caution to avoid damage. Your repair manual will guide you if this is necessary.
* Body Shop: If you are uncomfortable performing this repair yourself, or if you encounter significant rust or damage, it's best to take your vehicle to a qualified body shop or mechanic.
Again, a repair manual for your specific 2002 Ford Explorer is absolutely essential. Attempting this repair without one is highly discouraged due to the complexity and potential for damage. The steps outlined above are only a general guide and may not be completely accurate for your vehicle.
