2002 Zx2 window issue | Ford Escort Owners Association (FEOA)
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2002 Zx2 window issue

Discussion in 'Exterior Modifications' started by LTDteether, Jul 8, 2020.

  1. LTDteether

    LTDteether FEOA Member

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    The wife drives a 2002 Zx2 that now has a broken driver window. She got a replacement window on eBay since everyone told her that new ones are not available. It arrived, however, without the metal bracket and what I'd call a big bushing. The bracket is not so much of a problem because we have the one from the broken window. The big rubber donut on that bracket is decayed badly and that, like the window, is not available from the dealer, nor anywhere else she has looked. Does anyone here have a solution? It looks like maybe it could be finessed from another off the shelf part.
  2. novanutcase

    novanutcase FEOA Member

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    Can you send a picture of the part you are talking about? The donut....

    John
  3. LTDteether

    LTDteether FEOA Member

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    Sorry I did not see your response earlier. Thanks for looking and thinking about it. I should edit my notification settings, I guess.

    I'll get a pic posted soon. It will look more like a donut with some bites taken out of it since it is in such bad shape :) We've since found that the pass side is completely missing the bushing as I believe it would be proper to call it. It is no wonder that the window sounds like it flops around a lot. Right now, the boss that carries the bushing is the only thing holding the window in that rear track in somewhat less stable alignment than intended.

    There must be something similar on the bracket that the regulator attaches to and also ties to the window near its bottom/middle. These are what keep the window reasonably stable while allowing some self adjustment as it is being slid up and down on those two tracks. I have not yet been able to look into the regulator track to see if this bushing is the same or different from the one in the more rearward track. I think that there is one on the pass side because I can't move the window excessively in that area. It also seems like it must be of different design if it is still there and the others are so banged up or gone.

    I can't imagine that this is not a vary common problem given the age of the newest of these cars. (Note that my daily driver, Mercury, is old enough to drink.) If I can't find the OTS replacement, I might be able to find some sort of plastic wheel that fits reasonably well into the track. If I can, I will bevel the edges, cut the boss off of the bracket,and drill a hole in the bracket to mount the axle. Time to go look at the shelves at the big box stores for some kind of very small, but robust, caster I guess. That might be a hard combination to find.
  4. novanutcase

    novanutcase FEOA Member

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    As much as I like to refurbish the original equipment on my car, in this case I would think it would be way less headache and cost to buy an aftermarket unit. I'm assuming you have power windows so a power unit is not all that expensive. Since you'll be removing the door card anyways to get access to the regulator you may as well install a new one rather than relying on a 20+ year old electric motor that may or may not give up on you a week later. As you are experiencing, the nylon roller in the track is bad and trying to get another in is not going to be easy as these units are somewhat self contained as far as I could tell.

    Not sure if you have power or manual windows but here are two links for both parts off of Ebay. I saw a Rock Auto discount code floating around this site so you may want to compare pricing.

    Manual - $37
    https://www.ebay.com/i/164181099289...1291&msclkid=2cd2928f099a110c9f3ecdad5b234c6b

    Power - $65.74
    http://vi.raptor.ebaydesc.com/ws/eB...ategory=33706&pm=1&ds=0&t=1554702582000&ver=0

    Good Luck!

    John
  5. LTDteether

    LTDteether FEOA Member

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    Thanks, John. We don't need a regulator right now, or even anything directly attached to it besides a "complete window assembly".

    Please correct me if I am wrong. The facts that I am working with are that the windows are not available from aftermarket sources. The local Ford dealer said that the window is obsolete and not available for the (electric) driver door ZX2. This bushing is part of the rear window bracket. (The regulator attachment is to the bracket in the middle of the window. The bracket and bushing are part of the window according to the Ford parts information. Internet dealer parts departments indicate that they have windows, but you never know. Some of them list obsolete parts and then start looking for them when they get a request. That would come with a bracket and bushing and be the first choice if we did not already have a replacement window without the bushing.

    Note that some short years ago, we were looking for a new regulator for the pass side and found that they are not available, although the driver side is, aftermarket. Apparently, the demand for the pass side is lower enough that it has passed the point where reasonable profit can be made by manufacturing and stocking them. If that goes bad, I may have to look at trying to rebuild it. The trouble is, the car is really near or past the point that it is worth fooling around with. We may cut our losses with the used eBay window that does not have the bushing and try to find a new window (new old stock) or just go without the bushing and tolerate the poor operation until we replace the car. If we had to pay someone for labor to mess with this, the car would have been totaled weeks ago.

    I am seeing things listed as bearings with polyurethane tires, luggage wheels or other casters, and conveyor belt hardware that might be adapted. The trouble with casters is that anything small enough might not be robust enough for the task. We'll see. I just started looking at them yesterday. Busted bushingJPG.JPG

    Oh, here is another question. Do you know if conversion to crank windows, assuming that all the parts we'd need are available, is a reasonable path?
  6. novanutcase

    novanutcase FEOA Member

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    I guess you could convert your power windows to manual pretty easily as all the mount holes are in the door subframe. Having driven many a car with manual windows I can say that power windows are superior in functionality but to each his own.

    I'm a little confused. Do you need the actual window glass or do you just need the nylon roller that broke? You could find one from a junkyard but then you're sort of living on borrowed time as the roller will probably fail fairly soon....or not.

    If it was me and I was doing what you want to do I would go to a junkyard and pull the roller off one of the rear windows as those aren't used as much as the front side windows so you'll probably get more life out of that one.

    John

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