remove the door panel
remove the plastic sheet (save it)
move the window up/down until you can see the two rivets going through the glass, in the middle of two round white plastic pieces.
punch out the centers of the rivets
drill the heads off, that will get the glass off the slider and track
fully raise the glass and have someone hold it
unbolt the curved track, and remove the track and the slider
(leaving the window regulator, and motor if equipped, in the door)
now, unbolt the felt thing on the inside of the glass, near the door lock knob
lower the glass completely or mostly
remove the "window run weatherstripping" which is the rubber in the glass track (across the top and down the sides)
you will probably need new rubber
lift the glass up and out of the door...lift it straight up and out, since the door and glass curve, so lifting it straight up should get it out for you.
reverse instructions to install
pictures before disassembly are recommended
no problem man...you actually dont have to drill them all the way out, theyre aluminum. you just have to drill until the head seperates from the shank.
you can use a chisel for the window regulator / motor to door rivets, but i'd be scared to do that right on the glass. and remember to use rivets when putting it back together. bolts + glass = lots of little cubes everywhere. guess how i found this out
oh prolly about 20 bucks at harbor freight, the one i have. its just like the "big daddy" one that sells for like 120, but its just more cheaply made. DO NOT use cheap rivets though, get yourself a box of Marson 1/4" rivets from ebay for like 8 or 10 bucks, or from an auto body supply store. your local ford dealer might have a few as well.
Instead of rivets, you could use 1/4", stainless bolts with nylock nuts. I forget how long the bolts should be ( 1/2", 3/4", 1", ), but you don't want them too long. ANd you don't want to tighten the nuts too much -- just barely snug them up.
I did this replacing the window regulators on my Crown Vic. Since the CV's window regulators fail quite frequently, it's nice not to keep having to drill out rivets.
i hate drilling these things. my drill bit broke and i had to try to get the other one off without a bit. i tried a self tapping screw. i got the center out but still the rivet won't come out.i am getting the right bit tomorrow along with some fasteners. the ford truck i used to have had bolt on glass.