Here's a general outline of the process. Always refer to a repair manual specific to your year and model Windstar for precise instructions and diagrams. Variations exist between model years.
Tools You'll Need:
* Repair Manual: Essential for specific instructions and torque specs.
* Panel Removal Tools: Plastic pry tools to avoid scratching the interior trim.
* Screwdrivers: Phillips and possibly flathead, depending on your model year.
* Putty Knife (Plastic or Metal): For carefully removing old sealant.
* Utility Knife: To carefully cut away old sealant.
* Clean Rags: To clean the surfaces.
* Safety Glasses: To protect your eyes from broken glass.
* Gloves: To protect your hands.
* New Window: Ensure you get the correct replacement glass for your year and model.
* New Sealant: Use a high-quality automotive-grade urethane sealant.
* Caulk Gun: To apply the sealant.
* Measuring Tape: To ensure proper window placement.
Steps (General Outline - Consult Your Repair Manual):
1. Interior Panel Removal: Carefully remove the interior door panel. This usually involves removing screws, clips, and possibly disconnecting electrical connectors for power window switches or other components. Use plastic pry tools to avoid damage. Your repair manual will show you exactly where the fasteners are located.
2. Exterior Trim Removal: Remove any exterior trim pieces that may be obstructing access to the window.
3. Glass Removal: This is the most crucial and delicate step. You'll need to carefully remove the old window and the old sealant. Use a putty knife and/or utility knife to carefully separate the glass from the existing sealant. Work slowly and methodically to avoid breaking the glass. Be extremely careful; shattered glass is dangerous.
4. Clean the Frame: Thoroughly clean the window frame and the surrounding area of any old sealant, dirt, and debris. Use a degreaser if necessary. A clean surface is crucial for a proper seal.
5. Apply New Sealant: Apply a bead of automotive-grade urethane sealant to the window frame, following the manufacturer's instructions. This often involves a continuous bead around the perimeter of the frame.
6. Install the New Window: Carefully position the new window into the frame, ensuring it's properly aligned and seated.
7. Clean Excess Sealant: Immediately clean up any excess sealant that squeezes out.
8. Secure the Window: Some models may use clips or other mechanisms to hold the window in place while the sealant cures. Refer to your repair manual for the proper procedure.
9. Reassembly: Reinstall the exterior trim and interior door panel, ensuring everything is properly secured.
10. Allow Sealant to Cure: Allow the sealant to cure completely according to the manufacturer's instructions (usually several hours or overnight). This is crucial for preventing leaks.
Important Notes:
* Safety First: Wear safety glasses and gloves throughout the entire process.
* Take Pictures: Take pictures of each step during disassembly to help you with reassembly.
* Repair Manual: This is absolutely essential. The steps outlined above are general; your Windstar's specific model year will have variations.
* Professional Help: If you are not comfortable with this type of repair, it's best to take your Windstar to a professional auto glass shop. The cost of a professional repair might be less than the cost of a damaged window or the frustration of an improperly completed job.
This is a complex repair. Improper installation can lead to water leaks and safety hazards. Proceed with caution and always refer to your vehicle's repair manual for specific instructions.
