Well Lindzy Louis IV, here's how you do it.
Remove 3 Phillips screws (long ones) that are underneat the steering wheel. Once these are removed, 2 pieces will come off that covered the top and the bottom of where the key goes. Set these aside with it's screws.
Next using a 7mm socket, undo the 2 bolts holding the plastic piece where your knees sit by on the driver side.
Remove this panel and put it with the screws.
Now, remove all the screws you can find that aer attached to that big cluster where your gauges are. There are 9 I think but you can only get to a few at first. Remove what you can find. Now grab the headlight switch and pull it until it pops out a little. Use 2 screw drivers to hold the tabs down as you pull it out, and use the screw drivers to remove the wiring harness. Do the same with the other side (the rear window defroster and the hazard warning indicator switch.)
Now below the windshield there are 2 more screws holding that big instrument cluster bezel on (you'll have to use a tiny Philips screwdriver or a offset screwdriver to get them out. Once these are out, check again to make sure you removed all the screws you see. Now you should be able to maneuver the bezel out (the big piece surrounding the gauges.) Once that's out, remove the rest of the screws holding the instrument cluster on, pull it out a little, remove the speedometer cable and the 2 wiring harnesses, and that's it.
It is not difficult. First you have to remove the 12vot cigarette lighter plastic and then remove the radio. 4 screws for the radio. Then you have to remove the panel that goes from the radio up to the instrument cluster. This panel has 4 screws. 2 of them are on top of the instrument cluster (visible) and the other two should be visible after removal of radio.
Pull the hazard light button pocket, and remove the philips screw behind it. Remove the two philips screws on the under side of the dash, immediately above the dash instrument panel, and pull the trim panel out. Remove the four philips screws securing the dash instrument panel, and pull the panel out.
Disconnect the negative battery cable, remove the ashtray, grasp the center instrument panel bezel securely and pull it out, then unscrew the lower center module from the instrument panel. The two radio mounting screws will be readily apparent for you to unscrew. Pull the radio out and unscrew the negative strap from the back of the radio and remove the connectors and antenna lead. Installation is the reverse of removal.
Inside the van on the passengers side and its a very big job to replace it.........Disconnect the battery ground cable.Remove the engine cover.Remove the steering column-to-instrument panel bolts. Lower the column carefully.Remove the upper and lower instrument panel attaching screws. Remove the radio support bracket screw.Raise and support the right side of the instrument panel.Remove the lower right instrument panel bracket.Remove the vacuum actuator from the kick panel.Disconnect the temperature cable and vacuum hoses at the case. Remove the heater distributor duct from over the engine hump.Remove the two defroster duct-to-firewall attaching screws below the windshield.Under the hood, disconnect and plug the heater hoses at the firewall.Remove the three nuts and one screw (inside) holding the heater case to the firewall.Remove the case from the van. Remove the gasket for access to the screws holding the case together. Remove the temperature cable support bracket. Remove the screws and separate the case. Remove the heater core.
The A/C electronic blend door actuator is located on the top of the plenum housing. Its function is to move the air temperature blend door on command from the control assembly. The A/C electronic blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the electronic automatic temperature control module and is matched with the wiper voltage of the module potentiometer. The control module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the control module wiper voltage. Disconnect the battery. Remove the instrument panel steering column cover. Remove the RH and LH instrument panel lower insulator panels. Remove the steering column opening brace. Disconnect the steering shaft universal joint. Remove the RH and LH cowl side trim panels. Release the glove box door, and remove the two screws from the center instrument panel support. Remove the instrument panel defroster grille. Unclip the instrument panel defroster opening grille. Disconnect the connectors. Remove the instrument panel defroster opening grille. Remove the RH and LH upper moldings. Remove the three instrument panel cowl top screws. Remove the RH instrument panel cowl slide nut. Remove the upper LH instrument panel cowl side nut. Remove the lower LH instrument cowl side bolt Reposition the instrument panel rearwards. NOTE : Repositioning the instrument panel requires two technicians. Cut the insulator and position away from the actuator. Disconnect the connector. Remove the screws and remove the electronic blend door actuator. INSTALLATION Install the electronic blend door actuator. Connect the connector. Tape the insulator in position. Place the instrument panel in position. NOTE : Repositioning the instrument panel requires two technicians. Install the lower LH instrument panel cowl side bolt. Install the upper LH instrument panel cowl side nut. Install the RH instrument panel cowl side nut. Install the RH instrument panel cowl top screws. Install the three instrument panel defroster grille opening. Position the instrument panel defroster opening. Connect the connectors. Install the instrument panel defroster grille opening. Reach through the glove box door opening and install the two center support screws. Install the RH and LH cowl side trim panels. Connect the steering shaft universal joint. Install the instrument panel tunnel brace. Install the RH and LH instrument panel lower insulator panels. Install the instrument panel steering column cover. I know it seems a little complicated, but I believe we can do it! It say a novice should be about 4.3 hours... So get a 12 pack and have at it. I didn't see any special tools called for here. When they talk about "wiper" they are talking about the arm to the door that swings the door from hot to cold. I guess you could disconnect the arm in the warm position, but after spending that much time getting to it, it's only three bolts from replacing it.
To remove the door panel on a 1993 Mercury Cougar XR7, the first thing to do is to remove the lens covers from any lights in the door. The unscrew the light fixtures from the door. The door panel is attached by the use of clips. With a little nudging with a flat object, such as a screw driver, the clips will pop free of the metal.
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