posted 05-30-2006 08:27 PM                  

1. How do you know when the window regulator is broken? It may be broken and still seem to work, as mine did.

Answer: If it doesn't sound quite right, or like other power windows you've operated. It may make a very subtle ratcheting type noise. Also, If it doesn't go up all the way with the top up. If you close the window with the top up, it should go to the same height as with the top down. You can see this by checking the position of temper mark on the glass near the rear of the window. See picture:

2. What does the regulator look like, and how does it work?

Answer: The window regulator is a cable operated mechanism. In this particular case, it has a couple of inherent flaws, which make susceptible to failure. The cable drive is subjected to severe bending stresses and constant flexing, causing the cable jacket to eventually break. See picture:

3. How can this be repaired?

Answer: Here's what I did. The cable jacket needs to be reinforced to prevent it from breaking again (at least not as quickly). One way to do this is to thicken the walls of the cable jacket. Start by splitting a bigger tube to fit over the existing cable jacket:

The tube now needs to be secured around the existing cable jacket by bonding and clamping it in place. This will both hold the broken cable jacket together and prevent it from ever being stretched or broken again. I used a very strong double sided carpet tape to do the bonding.

posted 05-30-2006 09:12 PM                  

Next step is to add additional reinforcement around the broken and weak areas. I used some pool cue tips I had lying around. Then I clamped it all together with hose clamps. This makes a solid and permanent bond between the inner and new outer cable jacket. It is now a little more difficult to bend for reinsertion into the door, but well worth the effort.

posted 05-30-2006 09:17 PM                  

Finally, the cable drive assembly must be reinstalled into the door. A new cable clamp is required to accommodate the larger diameter of the cable jacket. This clamp also does a much better job of securing the cable and all but eliminating the excess flexing.

Note the location of all the fasteners that hold the glass and cable drive assembly to the door.

Remounting the moisture barrier on the inside of the door requires new adhesive. I found that the same carpet tape I used to bond the tubes together, also works well in this application.

In my case, this fix made a world of difference in the performance of the windows. They now go up and down quietly and positively. The window reaches exactly the same height with the top up or down and with the door closed.
I couldn’t be happier.

posted 05-30-2006 10:15 PM                  

Great detailed instructions.

posted 05-31-2006 07:58 AM                  

1. Regrease the cable and slide tracks while you have them out, as Catfish mentioned (I did).
2. Replace the (4) X-Mas tree clips used to hold the inner door panel in place. They don't work very well for a second application.
3. Adjust the window positions with the adjustment screws to align with the seals on the convertible top, giving even and secure compression along the entire length of the seals.
4. And most important, check your windows to see if the temper mark comes up to the same height with the top up, while the door is open and then closed.

You won't believe how much this improves the operation of the windows.

posted 06-01-2006 07:38 AM                  

I don't know who Eric is, but my name is Rainer Mueller, AKA Kraut.

The time it took to do the write-up is just about as long as it took to do the actual fix, but I thought it was worth it. I did it because it offers others a real solution to a difficult problem.

posted 06-01-2006 10:32 AM                  

I still have an older regulator that is in need of repair.

posted 06-17-2006 12:11 AM                  

quote:

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Originally posted by Kraut:
HipHop,

You are welcome. If you or anyone else would like a copy of a "Word" file with larger pictures, I can E-Mail it to you. You must have a cable modem, however, because it is a large file (9.5 meg). If you can't handle a file that size, I can snail mail a copy to you. Just give me your address.

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are you going to Louisville event?

You might make a few copies on CD and sell for a small fee

I would like a copy and have a cable modem but afraid it would couse it to lock up or be deleted by my anti virus software

very clear info on your repair/modification

------------------
Larry & Sue Mayes

posted 07-09-2007 02:29 AM                  

Once I get the interior panel off, how do I remove the glass and regulator assembly?

How long should this fix take?

Can you email me the word document?