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  Window Regulators - How they work and how to fix them (Page 1)

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Author Topic:   Window Regulators - How they work and how to fix them
Kraut



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posted 05-30-2006 08:27 PM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
Here we go again, and this time I got it right:

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.

More to follow: Please do not respond to this until I get all three pages posted.

Kraut



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posted 05-30-2006 09:12 PM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
I then put the new split tube in place over the existing cable jacket. This is a tricky operation, since the split tube is difficult to hold open while placing over the very sticky carpet tape.

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.

More to follow: Please do not respond to this until I get all the pages posted.

Kraut



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posted 05-30-2006 09:16 PM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
Here's the four pictures that didn't work in the last post:


Kraut



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posted 05-30-2006 09:17 PM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
I guess it was just slow to respond:

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.

Kraut



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posted 05-30-2006 09:27 PM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
Here's the last three pictures that didn't come across. This is really frustrating:


catfish




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posted 05-30-2006 09:31 PM     Click Here to See the Profile for catfish     send a private message to catfish   Edit/Delete Message   Reply w/Quote   Search for more posts by catfish
good job.let us know how it lasts.one other thing while you have the reg.out of the door regrease both tracks that the guides move up and down on.i have to regrease one of mine.it gets so hot here in az.that the grease tends to dry out causing a bind.

------------------

Ron Robb




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posted 05-30-2006 09:53 PM     Click Here to See the Profile for Ron Robb     send a private message to Ron Robb   Edit/Delete Message   Reply w/Quote   Search for more posts by Ron Robb
Wow! Excellent visual aid. I've been following the different ideas on how to fix, - which fortunately I have not yet had to face - but could never really picture the set-up. This is a great help and looks like a promising fix. Thanks for taking the time to do all the photos and labeling!!!
Howard


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posted 05-30-2006 10:15 PM     Click Here to See the Profile for Howard     send a private message to Howard   Edit/Delete Message   Reply w/Quote   Search for more posts by Howard
Kraut:

Great detailed instructions.

Thank you

ed monahan




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posted 05-30-2006 10:52 PM     Click Here to See the Profile for ed monahan     send a private message to ed monahan   Edit/Delete Message   Reply w/Quote   Search for more posts by ed monahan
Kraut, Excellent job. I am going nominate you for an Emmy, or Oscar or something. Great job.
toys


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posted 05-30-2006 11:12 PM     Click Here to See the Profile for toys     send a private message to toys   Edit/Delete Message   Reply w/Quote   Search for more posts by toys
Very Nice

Toys

BeWare




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posted 05-30-2006 11:13 PM     Click Here to See the Profile for BeWare     send a private message to BeWare   Edit/Delete Message   Reply w/Quote   Search for more posts by BeWare
Awesome work. Thank You
Kraut



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posted 05-31-2006 07:58 AM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
Thanks for the compliments. Here are a couple of notes I forgot:

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.

Another note: I mentioned in my prior post on this subject, that I wasn't sure if the break in my cable jackets were fractures or designed in features. I'm still not sure. The breaks in my cable jackets were in my opinion too clean to be stress related fractures. They were perfectly straight and smooth on both cables, as well as being in the same location. I think this may be an attempt at some sort of safety feature, reducing the risk of pinching as the window goes up. Unfortunately, it is also a design feature which almost guarantees poor function of the windows going to the closed position. Does anyone know for sure?

Feral
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posted 05-31-2006 10:15 AM     Click Here to See the Profile for Feral     send a private message to Feral   Edit/Delete Message   Reply w/Quote   Search for more posts by Feral
Great Job Eric, Thank you for taking the time to document your efforts. Just labeling the pictures probably took longer than the repair. I'll certainly refer to your work on that dark day when my regulators break. Outstanding work.
Scott
quincy


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posted 05-31-2006 07:41 PM     Click Here to See the Profile for quincy     send a private message to quincy   Edit/Delete Message   Reply w/Quote   Search for more posts by quincy
Eric,
Excellent Job!! I agree with Ed, you should get some kind of documentation award for your efforts. The repair does not look like a pleasant task. Your hard work is very appreciated by the group!
catfish




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posted 05-31-2006 08:51 PM     Click Here to See the Profile for catfish     send a private message to catfish   Edit/Delete Message   Reply w/Quote   Search for more posts by catfish
in your lat photo,that is the break.let me know how long it.lasts.nice labeling.you must have alot of time on your hands.

------------------

Kraut



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posted 06-01-2006 07:38 AM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
Eh guys,

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.

------------------

TooHipCat


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posted 06-01-2006 10:32 AM     Click Here to See the Profile for TooHipCat     send a private message to TooHipCat   Edit/Delete Message   Reply w/Quote   Search for more posts by TooHipCat
Thank You Kraut for starting and finishing this very informative thread!!!

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

Brian

Kraut



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posted 06-01-2006 12:35 PM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts 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.

Kraut



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posted 06-01-2006 12:40 PM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
Brian, sorry about the name screw-up. I also just remembered that my color printer is broken, so I can't send the file by snail mail. Black and white, just doesn't do it justice.
TFischer




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posted 06-15-2006 01:51 PM     Click Here to See the Profile for TFischer     send a private message to TFischer   Edit/Delete Message   Reply w/Quote   Search for more posts by TFischer
Rainer: Great information. Thanks for taking the time to post it!! Tami
CJ




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posted 06-15-2006 09:12 PM     Click Here to See the Profile for CJ     send a private message to CJ   Edit/Delete Message   Reply w/Quote   Search for more posts by CJ
Awesome job, Rainer!
WildCat




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posted 06-17-2006 12:11 AM     Click Here to See the Profile for WildCat     send a private message to WildCat   Edit/Delete Message   Reply w/Quote   Search for more posts by WildCat
quote:
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.


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

Kraut



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posted 06-18-2006 11:33 AM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
That's a great idea Larry. I will make some CD copies for anyone interested, and sell them for $1.00, just to cover the cost of the CD's and cases. I'll bring them to Louisville.

See you there, Kraut

NeverBland

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posted 07-09-2007 02:29 AM     Click Here to See the Profile for NeverBland     send a private message to NeverBland   Edit/Delete Message   Reply w/Quote   Search for more posts by NeverBland
Good info, a little help please:

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?

Thanks

Kraut



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posted 07-09-2007 06:30 AM     Click Here to See the Profile for Kraut     send a private message to Kraut   Edit/Delete Message   Reply w/Quote   Search for more posts by Kraut
Neverbland,
Send me a PM with your e-mail address and I'll send you the file. Be advised, that it is almost 10meg, so you will need cable modem high speed internet.

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