2009
23
The Switch Repair is not recommended for people with TMP and Warranty, unless stuck in the wilderness somewhere without an Open Driver’s Window.
The process is simple and illustrated step by step. The Tools Required for this whole exercise is fairly basic. Any market available screw driver set would do the job properly. Having a sturdy one would help.
This lineup should be enough to finish the Job.
The first step is locating and checking how everything is at the beginning of the operation.
The front driver side switch on the Ford Fusion and some models of Fiesta. This particular object has a very high failure rate, and if you are stuck with the driver side window 'Up', it can be very irritating.
To get started with the DIY process, you need to get the things mentioned in step one. Using the nail puller, gently get the Switch Console out of the door panel. The Switch Console is fastened with two spring steel clips on either side.
Take note to pull it out evenly from all side. This is necessary to retain the cables inside in their original position.
When the console is fully out, gently tilt it over away from the panel to have access to all wires
You will notice that the unit is attached using two wire clusters fastened with a Snap Fit. One should be White in color and the other one Black. The White one carries the wires for the window and the black one carries the wires for the rear window lock.
Take out the white wire cluster followed by the other one. Notice that the Snaps will be positioned on the side, for the Black one it will be on the front (in reference to the car).
Locate the second snap fit, and get it loose by gently pushing it down with a Screw Driver.
Slide the wire cluster out of the switch console.
Locate the Snap Fits that are holding the top and the bottom portions of the Switch Console.
Push the snaps out gently with a very thin screw driver. This may take some patience as they have a habit of snapping back promptly.
Separate the top and bottom parts pulling them outwards, away from each other. Take care to not tilt as it may damage the small LEDs that are used to light up the switches. A few may get bent a little, but that's not much of a worry.
This image clearly shows the position of each LED and the two springs that push the 'Rear Window Override' switch.
Marked in red are the contact points for the Driver Side window switch. Clean these as they may have Carbon, Grease, Oxidation and other residues on them which hampers the connection. While you are at it, may as well clean the others too.
We can pretty much forget about the top part after cleaning the contacts. They can be cleaned with nail Polish Remover, if you are traveling with your wife or girlfriend, chances are they will have one in their purse.
You can also see three springs that are sticking out from the top part. They are to hold the switch console within the door panel. Do not move them much from their position.
The bottom part of the Switch Console will have an array of springs. Marked in red are the ones that are responsible for the Driver's Window.
A close up of the springs. Note that they are a little curved. The spring is supposed to make contact with the point at all times. Breaking the contact moves the window up or down. Also, remember the springs.
Note: The springs are very integral to the switch operation and loosing them can spell complete disaster.
It is possible to find matching springs from a Ball Point pen if desperation calls. Try and not loose them to begin with.
Another close up of the spring and the LEDs
Gently push the springs up to see if there is any loose fit. Although that is very unlikely.
This part of the process will need a lot of concentration. Would suggest a good cup of coffee before getting on with this. At first, all the springs inside will look alike. It’s only on close observation you will notice that the one’s for the Driver’s Window do not touch their respective contacts on top.
Gently push up the curved part of the sprint to build back the lost tension due to repeated use of the switch. Yes, that is the main cause for this regular malfunction.
Check the alignment of the springs by holding the whole thing parallel to the ground lined up straight. They should all line up like Guards at a Parade.
You are done cooking. Take care of the LEDs, and the Springs. And start assembling the whole thing together. This will be a lot faster, but take care to not leave anything abandoned outside.
Align the springs properly. If they do not align, they will come loose and eventually may cause a Shirt Circuit.
Snap the whole thing shut and reverse the process earlier to put it back into the door. Put the wire clusters to where they belong, and you are ready to go.
Also note that this process will surely violate any Warranty available on the vehicle unless you manage to finish the Job very clean. The ford parts that fit inside are not that well finished and it might be easy to get away without being noticed. Chances are that the switch won’t trouble you for another year or more. It’s way easier and cheaper if you think of the Rs 3500/- (approx) that will pay for a new console and the time that you might have to wait due to permanent non availability of parts. This process is more useful if you are stuck without an open window in the middle of a highway to nowhere and the nearest Ford Service many hours away.
Thanks. Anytime!
Did not want to remove the door panel fearing increase in rattle post operation. Need to repair the passenger side switch within the same console as we speak.
Das
I resolved my problem with the given instruction.I certainly owe you a beer !
(Note : Perhaps its easier to remove the plastic covering around the door handle with the switch console on it than trying to pull out switch console alone – less scratches ..)