Section 01-11: Glass, Frames and Mechanisms | 1996 F-150, F-250, F-350, F-Super Duty and Bronco Workshop Manual |
DIAGNOSIS AND TESTING
Pinpoint Tests
NOTE: Using Rotunda Digital Volt-Ohmmeter 014-00407 or equivalent, perform electrical pinpoint tests.
PINPOINT TEST A: POWER WINDOWS COMPLETELY INOPERATIVE
A1 CHECK 20A CIRCUIT BREAKER
- Check 20A circuit breaker located in IP fuse panel.
Is circuit OK?
A2 CHECK SYSTEM
- Replace 20A circuit breaker.
- Key to RUN/ACC.
- Operate power window system.
- Inspect circuit breaker.
Does circuit breaker fail again?
A3 CHECK FOR POWER SHORT TO GROUND
- Key off.
- Locate and disconnect window regulator control switch connector, and the passenger window regulator control switch connectors.
- Measure resistance between Circuit 400 (LB/BK) at IP fuse panel and ground.
Is resistance less than 5 ohms?
| Yes | No |
|---|
| SERVICE Circuit 400 (LB/BK) between the power window regulator control switches and IP fuse panel and REPLACE circuit breaker. | GO to A4. |
A4 CHECK FOR SHORT TO GROUND
- With key off, disconnect master power window regulator control switch connector.
- Measure resistance between the master power window regulator control switch connectors 334 (R/Y), 333 (Y/R), 313 (W/Y), 314 (T/LB), 170 (R/LB), 316 (Y/LB), 317 (GY/O), 319 (Y/BK), 320 (R/BK) wires and ground.
Any resistance less than 5 ohms?
| Yes | No |
|---|
| SERVICE the circuit in question for a short to ground and REPLACE circuit breaker. | GO to A5. |
A5 CHECK MASTER POWER WINDOW REGULATOR CONTROL SWITCH GROUND
- With key off, disconnect master power window regulator control switch connector.
- Measure resistance between the Circuit 57 (BK) wire between master regulator control switch connector and ground.
Is resistance less than 5 ohms?
| Yes | No |
|---|
| GO to A6. | SERVICE the open circuit in question. |
A6 CHECK MASTER POWER WINDOW REGULATOR CONTROL SWITCH
- With key off, remove master power window regulator control switch. Leave the electrical connector connected.
- Key to RUN/ACC.
- Check voltage of master power window regulator control switch as shown in tables below, while operating window regulator control switch.
| Power Window | Switch Position | Circuit/Wire Color |
|---|
| 227 (Y) | 226 (W/BK) | 313 (W/Y) | 314 (T/LB) |
|---|
Left
Front | Up
Down | 12V
0V | 0V
12V | 0V
0V | OV
0V |
Right
Front | Up
Down | 0V
0V | 0V
0V | 12V
0V | 0V
12V |
| Power Window | Switch Position | Circuit/Wire Color |
|---|
| 317 (GY/O) | 316 (Y/LB) | 320 (R/BK) | 319 (Y/BK) |
|---|
Left
Rear | Up
Down | 12V
0V | 0V
12V | 0V
0V | 0V
0V |
Right
Rear | Up
Down | 0V
0V | 0V
0V | 12V
0V | 0V
12V
|
NOTE: 12V (B+) = (10V - 14V), 0V = (0V - 1V)
Is voltage for all switch positions within specifications?
| Yes | No |
|---|
| GO to A7. | REPLACE master power window regulator control switch. |
A7 CHECK POWER SUPPLY TO PASSENGER WINDOW REGULATOR CONTROL SWITCH
- With key off, disconnect passenger power window regulator control switch connector.
- Key to RUN/ACC.
- Measure voltage on Circuit 400 (LB/BK) wire at passenger power window regulator control switch connector.
Is voltage greater than 10 volts?
| Yes | No |
|---|
| GO to A8. | SERVICE Circuit 400 (LB/BK) wire between passenger window regulator control switch and IP fuse panel. |
A8 CHECK PASSENGER WINDOW REGULATOR CONTROL SWITCH
- Key off.
- Reconnect the master window regulator control switch.
- Remove the passenger window regulator control switch. Leave the electrical connector connected.
- Key to RUN/ACC.
- Check for voltage at the passenger window regulator control switch, as shown in the table below, while moving the window regulator control switch.
| Switch Position | Wire Color |
|---|
| 313(W/Y) | 314(T/LB) |
|---|
| UP | 12V | 0V |
| DOWN | 0V | 12V |
NOTE: 12V = (10V-14V), 0V = (0V-1V)
Are the voltages for all switch positions within specifications?
| Yes | No |
|---|
| GO to A9. | REPLACE the passenger window regulator control switch. |
A9 CHECK PASSENGER WINDOW REGULATOR CONTROL SWITCH WIRE CONTINUITY
- Key off.
- Disconnect the passenger power window regulator control switch connector and the right power window regulator electric drive connector.
- Measure the resistance of the following wires between the passenger power window regulator control switch connector and the right power window regulator electric drive connector.
| Passenger Power Window Switch | Right Window Regulator Electric Drive |
|---|
| 313(W/Y) | 333(Y/R) |
| 314(T/LB) | 334(R/Y) |
Are the resistances less than 5 ohms?
| Yes | No |
|---|
| REPLACE the right window regulator electric drive. | SERVICE the wire(s) in question. |
PINPOINT TEST B: SINGLE POWER WINDOW INOPERATIVE
B1 DETERMINE INOPERATIVE WINDOW
Is passenger door window inoperative?
B2 CHECK INOPERATIVE WINDOW POWER SUPPLY
- Remove left window regulator control switch per outline.
- Using test lamp, connect lead to a known good ground.
- Using chart below, connect test lamp to appropriate circuit.
- Actuate window regulator control switch in appropriate direction and observe test lamp.
| Pin | Circuit | Circuit Function |
|---|
| 15 | 226 (W/BK) | Left Front Window Up |
| 8 | 227 (Y) | Left Front Window Down |
| 13 | 314 (T/LB) | Right Front Window Down |
| 6 | 313 (W/Y) | Right Front Window Up |
| 10 | 317 (GY/O) | Left Rear Window Up |
| 12 | 316 (Y/LB) | Left Rear Window Down |
| 11 | 320 (R/BK) | Right Rear Window Up |
| 13 | 319 (Y/BK) | Right Rear Window Down |
Did test lamp illuminate?
| Yes | No |
|---|
| GO to B3. | REPLACE window regulator control switch. RESTORE vehicle. RETEST system. |
B3 CHECK INOPERATIVE WINDOW MOTOR CIRCUITS
- Gain access to inoperative window regulator electric drive connector as outlined.
- Disconnect window regulator electric drive connector.
- Connect test lamp lead to a known good ground.
- Using chart below, connect other end of test lamp to appropriate circuit.
- Actuate window regulator control switch in proper direction and observe test lamp.
| Pin | Circuit | Circuit Function |
|---|
| 15 | 226 (W/BK) | Left Front Window Up |
| 8 | 227 (Y) | Left Front Window Down |
| 6 | 333 (Y/R) | Right Front Window Up |
| 10 | 334 (R/Y) | Right Front Window Down |
| 4 | 333 (Y/R) | Left Rear Window Up |
| 2 | 334 (R/Y) | Left Rear Window Down |
| 4 | 333 (Y/R) | Right Rear Window Up |
| 2 | 334 (R/Y) | Right Rear Window Down |
Did test lamp illuminate?
B4 CHECK CIRCUIT CONTINUITY
- Disconnect left window regulator control switch.
- Using ohmmeter, check resistance of suspect circuit between harness connector and left window regulator control switch.
Is resistance 5 ohms or less?
| Yes | No |
|---|
| GO to B5. | SERVICE open circuit. RESTORE vehicle. RETEST system. |
B5 CHECK POWER WINDOW MOTOR
- Using a jumper wire, connect one end to battery positive, connect other end to Pin 1 at window regulator electric drive.
- With a second jumper wire, connect one end to a known good ground. Momentarily connect other end of jumper wire to Pin 2 of window regulator electric drive.
- To reverse window regulator electric drive direction, switch jumper leads at window regulator electric drive.
Did window regulator electric drive operate correctly?
| Yes | No |
|---|
| Power window OK. RESTORE vehicle. RETEST system. | REPLACE window regulator electric drive. RESTORE vehicle. RETEST system. |
B6 CHECK INOPERATIVE PASSENGER DOOR WINDOW
- Remove right window regulator control switch as outlined.
- Using a test lamp, connect one end to a known good ground.
- Connect other end to Circuit 313 (W/Y).
- Actuate right window regulator control switch at left front door in the DOWN position. Observe test lamp.
- Disconnect test lamp from Circuit 313 (W/Y), and connect test lamp to Circuit 314 (T/LB).
- Actuate window regulator control switch in the UP position. Observe test lamp.
Did test lamp illuminate in either direction?
| Yes | No |
|---|
| GO to B7. | SERVICE open circuit between left and right window regulator control switches. RETEST system. |
B7 TEST CIRCUIT 400 (LB/BK)
- At RH window regulator control switch, test for battery voltage at Circuit 400 (LB/BK).
Is there battery voltage?
| Yes | No |
|---|
| GO to B8. | SERVICE open in Circuit 400 (LB/BK). RETEST system. |
B8 TEST RH WINDOW REGULATOR CONTROL SWITCH
- Connect test lamp to good ground.
- Connect other test lamp lead to Circuit 333 (Y/R).
- Actuate RH window regulator control switch to DOWN position.
- Move the test lamp lead from Circuit 333 (Y/R) to 334 (R/Y).
- Actuate RH window regulator control switch to UP position.
Did test lamp light on either circuit?
| Yes | No |
|---|
| GO to B9. | REPLACE RH window regulator control switch. RETEST system. |
B9 TEST WINDOW REGULATOR ELECTRIC DRIVE
- Access and disconnect the RH window regulator electric drive.
- Using a jumper wire, apply battery voltage to Pin 1 of the window regulator electric drive.
- With another jumper wire, momentarily apply a ground to Pin 2 of the window regulator electric drive.
Does the window regulator electric drive operate?
| Yes | No |
|---|
| SERVICE the open in Circuit 333 (Y/R) or 334 (R/Y). RETEST the system. | REPLACE the window regulator drive. RETEST the system. |
PINPOINT TEST C: POWER TAILGATE WINDOW INOPERATIVE
C1 TAILGATE POWER WINDOW INOPERATIVE
- Verify tailgate is completely latched.
- Using master tailgate switch, operate tailgate power window.
Does tailgate power window operate at master tailgate switch?
C2 VERIFY TAILGATE WINDOW SWITCH
- Verify tailgate is completely latched.
- Insert key to operate power tailgate window.
- Operate in both directions.
Does tailgate power window operate?
| Yes | No |
|---|
| CHECK for corrosion, unseated connectors and terminals. ROAD TEST vehicle and RETEST. | GO to C10. |
C3 CHECK CIRCUIT BREAKER MASTER CIRCUIT
- Check the 20A circuit breaker (number 14) located in the IP fuse panel.
Is the circuit breaker OK?
C4 CHECK SYSTEM MASTER TAILGATE WINDOW SWITCH
- Replace the 20A power window circuit breaker (number 14).
- Turn key to RUN/ACC.
- Operate the power window system.
- Inspect the circuit breaker.
Does the circuit breaker fail again?
C5 CHECK FOR POWER SHORT TO GROUND MASTER CIRCUIT
- Key off.
- Locate and disconnect the IP fuse panel connector.
- Locate and disconnect the master tailgate window switch connector.
- Measure the resistance between Circuit 400 (LB/BK) at the IP fuse panel connector and ground.
Is the resistance less than 5 ohms?
| Yes | No |
|---|
| SERVICE Circuit 400 (LB/BK) between the master tailgate window switch and IP fuse panel. | GO to C6. |
C6 CHECK FOR SHORT TO GROUND, CIRCUITS 404 AND 405
- Key off.
- Disconnect the master tailgate window switch connector.
- Measure the resistance between the master tailgate window switch connector 404 (P/LG) and 405 (P/LB) wires and ground.
Are any resistances less than 5 ohms?
| Yes | No |
|---|
| SERVICE the circuit in question for a short to ground and RETEST. | RECONNECT the IP fuse panel. GO to C7. |
C7 CHECK POWER SUPPLY TO MASTER TAILGATE WINDOW SWITCH
- Key off.
- Disconnect the master tailgate window switch connector.
- Key on.
- Measure the voltage on the 400 (LB/BK) wire at the master tailgate window switch connector.
Is the voltage greater than 10 volts?
| Yes | No |
|---|
| GO to C8. | SERVICE the Circuit 400 (LB/BK) wire between the master tailgate window switch and IP fuse panel. |
C8 CHECK MASTER TAILGATE WINDOW SWITCH GROUND
- Key off.
- Disconnect the master tailgate window switch connector.
- Measure the resistance of Circuit 57 (BK) wire between the master tailgate window switch connector and ground.
Is the resistance less than 5 ohms?
| Yes | No |
|---|
| GO to C9. | SERVICE the Circuit 57 (BK) ground wire. |
C9 CHECK MASTER TAILGATE WINDOW SWITCH
- Key off.
- Remove the master tailgate window switch. Leave the electrical connector connected.
- Key to RUN/ACC.
- Check for voltage at the master tailgate window switch, as shown in the table below, while moving the tailgate window switch.
| Power Window | Switch Position | Circuit/Wire Color |
|---|
| 404 (P/LG) | 405 (P/LB) |
|---|
| Rear | UP | 12V | 0V |
| | DOWN | 0V | 12V |
NOTE: 12V = (10V-14V), 0V = (0V-1V)
Is the voltage for all switch positions within specifications?
| Yes | No |
|---|
| GO to C10. | REPLACE master tailgate window switch. |
C10 CHECK CIRCUIT BREAKER TAILGATE WINDOW SWITCH
- Check the 20A circuit breaker (number 12) located in the IP fuse panel.
Is the circuit breaker OK?
C11 CHECK SYSTEM POWER SUPPLY
- Replace the 20A power window circuit breaker (number 12).
- Key to RUN/ACC.
- Operate the power window system.
- Inspect the circuit breaker.
Does the circuit breaker fail again?
C12 CHECK FOR POWER SHORT TO GROUND
- Key off.
- Remove the screws from the tailgate inner cover panel to gain access to the tailgate window electric drive.
- Locate and disconnect the IP fuse panel 20A circuit breaker.
- Locate and disconnect the tailgate lock window switch connector.
- Measure the resistance between Circuit 171 (BK/W) at the IP fuse panel connector and ground.
Is the resistance less than 5 ohms?
| Yes | No |
|---|
| SERVICE Circuit 171 (BK/W) between the tailgate window switch and IP fuse panel. | GO to C13. |
C13 CHECK FOR SHORT TO GROUND
- Key off.
- Disconnect the tailgate window switch connector.
- Measure the resistance between the tailgate window switch connector 333 (Y/R), 407 (T/BK) wires and ground.
Are any resistances less than 5 ohms?
| Yes | No |
|---|
| SERVICE the circuit in question for a short to ground. | RECONNECT the IP fuse panel. GO to C14. |
C14 CHECK POWER SUPPLY TO TAILGATE POWER WINDOW SWITCH
- Key off.
- Disconnect the tailgate window switch connector.
- Measure the voltage on the 517 (BK/W) wire at the tailgate window switch connector.
Is the voltage greater than 10 volts?
| Yes | No |
|---|
| GO to C15. | SERVICE the 517 (BK/W) wire between the tailgate window switch and IP fuse panel. |
C15 CHECK TAILGATE WINDOW SWITCH GROUND
- Key off.
- Disconnect the tailgate window switch connector.
- Measure the resistance of the 404 (P/LG) and 405 (P/LB) wires between the tailgate window switch connector and ground.
Is the resistance less than 5 ohms?
| Yes | No |
|---|
| GO to C16. | SERVICE the 404 (P/LG) and/or 405 (P/LB) wires. |
C16 CHECK TAILGATE WINDOW SWITCH
- Key off.
- Check for voltage at the tailgate window switch, as shown in the table below. Operate the tailgate window switch with key.
| Power Window
| Switch Position | Circuit/Wire Color |
|---|
| 333(Y/R) | 407 (T/BK) |
|---|
| Rear | UP | 12V | 0V |
| | DOWN | 0V | 12V |
NOTE: 12V = (10V-14V), 0V = (0V-1V)
Is the voltage for all switch positions within specifications?
| Yes | No |
|---|
| GO to C17. | REPLACE tailgate power window switch. |
C17 CHECK POWER SUPPLY TO TAILGATE LATCH SWITCH
- Key off.
- Disconnect the tailgate latch switch connector.
- Turn key to DOWN position.
- Operate tailgate latch switch and measure the voltage on the 334 (R/Y) wire at the tailgate latch switch connector.
Is the voltage greater than 10 volts?
| Yes | No |
|---|
| GO to C18. | REPLACE tailgate latch switch. |
C18 CHECK TAILGATE POWER WINDOW MOTOR CONTINUITY
- Key off.
- Disconnect the tailgate power window motor connector.
- Measure the resistance of the tailgate power window motor. Refer to Component Test for Window Regulator Electric Drive.
Are the resistances less than 5 ohms?
| Yes | No |
|---|
| REPLACE the rear window electric drive. | SERVICE the wire(s) in question. |
PINPOINT TEST D: WINDOW STUCK/BINDING
D1 CHECK FOR OBSTRUCTION
- Inspect the glass run for foreign objects or debris.
- Inspect inside the door for possible obstruction of the window regulator movement.
Is there a door window glass obstruction?
| Yes | No |
|---|
| REMOVE obstruction and RETEST. | GO to D2. |
D2 LUBRICATION CHECK
- Observe window movement to determine if condition is caused only by lack of lubrication: No obstructions, damaged, loose or misaligned parts.
Is there a lubrication concern?
| Yes | No |
|---|
| LUBRICATE as necessary. REFER to the procedures in Lubrication portion of this section. | GO to D3. |
D3 FRONT DOOR BELT LINE WEATHERSTRIP CHECK
- Inspect both front door belt line weatherstrip for proper installation.
Is there a weatherstrip concern?
| Yes | No |
|---|
| ALIGN and INSTALL the weatherstrip and RETEST. | GO to D4. |
D4 CHECK DOOR GLASS RUN RETAINERS AND WINDOW REGULATOR
- Inspect the door glass run retainers inside the door for proper installation and alignment.
- Inspect the window regulator for proper installation.
Is there a run retainer or regulator concern?
| Yes | No |
|---|
| CORRECT installation or alignment as necessary. REFER to Door Window Glass in the Adjustments portion of this section. | DETERMINE the worn or damaged component and REPAIR or REPLACE as necessary. |
PINPOINT TEST E: REAR WINDOW WILL NOT DEFROST
E1 CHECK REAR WINDOW DEFROST SUPPLY
- Remove heated back window switch and light as outlined.
- Key to RUN.
- With test lamp connected to a known good ground, back-probe Circuit 8 (O/Y).
Did test lamp illuminate?
E2 CHECK REAR WINDOW DEFROST GROUND
- Using ohmmeter connected to known good ground, connect other lead to Circuit 57 (BK).
- Measure resistance.
Is resistance 5 ohms or less?
| Yes | No |
|---|
| GO to E3. | SERVICE open in Circuit 57 (BK). RESTORE vehicle. RETEST system. |
E3 CHECK FUSE 7 REAR WINDOW DEFROST SUPPLY CIRCUIT
- Remove Fuse 7 (15A) at IP fuse panel.
- Using ohmmeter, check resistance between fuse output and Circuit 8 (O/Y).
Is resistance 5 ohms or less?
| Yes | No |
|---|
| GO to E4. | SERVICE open in Circuit 8 (O/Y). RESTORE vehicle. RETEST system. |
E4 CHECK REAR WINDOW DEFROST SUPPLY FOR SHORT
- Using ohmmeter connected to known good ground, connect other lead to Circuit 8 (O/Y). Read resistance.
Is resistance 5 ohms or less?
| Yes | No |
|---|
| SERVICE short to ground Circuit 8 (O/Y). REPLACE Fuse 7 (15A). RESTORE vehicle. RETEST system. | REINSTALL Fuse 7 (15A). GO to E5. |
E5 CHECK GRID FEED TO DEFROST RELAY
- Check output side of rear defrost fuse in power distribution box with test lamp.
Did test lamp illuminate?
E6 CHECK GRID SUPPLY FOR SHORT TO GROUND
- Using ohmmeter connected to known good ground, connect other lead to output side of rear defrost Fuse (30A).
Is resistance 5 ohms or less?
| Yes | No |
|---|
| SERVICE short to ground Circuit 185 (BK). REPLACE rear defrost Fuse (30A). RESTORE vehicle. RETEST system. | GO to E7. |
E7 CHECK GRID SUPPLY FOR OPEN CIRCUIT
- Using test lamp connected to known good ground, connect other end to Circuit 185 (BK) at rear defrost relay.
Did test lamp illuminate?
| Yes | No |
|---|
| GO to E8. | SERVICE open in Circuit 185 (BK). RESTORE vehicle. RETEST system. |
E8 CHECK RELAY OUTPUT TO GRID
- With test lamp still connected to known good ground, connect other end to Circuit 186 (BR/LB).
- Turn key to ON.
Did test lamp illuminate?
| Yes
| No |
|---|
| GO to E9. | REPLACE heated back window switch and light. RESTORE vehicle. RETEST system. |
E9 CHECK REAR WINDOW DEFROST GRID FEED
- Disconnect heated back window switch and light.
- Disconnect feed wire at rear window.
- Connect one lead of ohmmeter to known good ground; connect other lead to Circuit 186 (BR/LB).
- Measure resistance.
Is resistance 5 ohms or less?
| Yes | No |
|---|
| SERVICE Circuit 186 (BR/LB) for short to ground. RESTORE vehicle. RETEST system. | GO to E10. |
E10 CHECK REAR WINDOW DEFROST GRID FEED FOR OPEN
- Using ohmmeter, connect one lead to Circuit 186 (BR/LB) at heated back window switch and light. Connect other lead to window connector.
- Measure resistance.
Is resistance 5 ohms or less?
| Yes | No |
|---|
| GO to E11. | SERVICE open in Circuit 186 (BR/LB). RESTORE vehicle. RETEST system. |
E11 CHECK GRID GROUND
- Using ohmmeter, connect one lead to ground connector at grid.
- Connect other lead to known good ground.
- Measure resistance.
Is resistance 5 ohms or less?
| Yes | No |
|---|
| System OK. RESTORE vehicle. RETEST system. | SERVICE open in Circuit 57 (BK) at rear window grid. RESTORE vehicle. RETEST system. |
PINPOINT TEST F: REAR WINDOW DEFROSTER WILL NOT SHUT OFF AUTOMATICALLY
F1 VERIFY SWITCH
- Key off.
- Remove rear window defrost switch as outlined in this section.
- With switch at OFF, measure continuity between terminals 1, 3 and 1, 5.
Is there continuity?
| Yes | No |
|---|
| REPLACE heated back window control assembly relay/timer. | Switch OK. |