Date:         Thu, 17 Sep 1998 19:26:23 -0500
Reply-To:     Bill Urban <KC-Sadie-VW@WEBTV.NET>
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         Bill Urban <KC-Sadie-VW@WEBTV.NET>
Subject:      Power window regulator fix ('91 Carat)
Comments: To: Vanagon@VANAGON.COM
Content-Type: Text/Plain; Charset=US-ASCII

When I tried to install my new $160.00 power window regulator in the
driver's door of my van it got caught on something inside the door. In
the process of trying to free it I broke it. You can imagine my
frustration. Looking at the broken part it was obvious that it  was
broke in exactly the same place as the regulator  I had  oriiginally
removed. At the bottom of the metal track that the window travels on,
the cable goes thru a (1)plastic corner piece that attaches to the track
by a  small plastic fastening device and it's own "clip" that hooks thru
the track. The fastening device is two pieces:(2) a small corner piece
with a whole in it, and(3) a plastic pin that does the actual work of
holding the assembly to the track. This pin was broke on both of my
regulators. Must be a common problem. Buying another reg. was not an
option, so I  fixed the  problem in this design weakness. Instead of the
flimsy <1/8th" plastic pin I used a small metric machine screw,3 or 4
washers, a nut, and blue LOCTITE thread locker.

First pull the (1) corner piece back in place so you can hook it to the
track and clamp it there with a small c-clamp. This is tricky because of
the spring tension. Then position  (2) in place and insert the screw
where the (3)pin had been, head against the plastic. I taped this
temporarily. Then flip the assembly over  and use a needle nose pliers
to insert your washers into the metal recess around the screw you
installed, use enough to get  the spot where your new nut is going to be
accessable to an open end wrench. When your ready to install the nut
apply some LOCTITE to the nut and screw, it won't take much. Tighten the
screw snug while holding the nut. Don't overtighten and crack the
plastic. When finished remove the c-clamp and the regulator is fixed and
much stronger than a new one.

When reinstalling the regulator it is possible to do it without twisting
the whole assembly 180 degrees as the Bentley Manual shows if you use
caution and go slow.

Hopefull this fix will save someone some money.

LATER!

Bill Urban
Kansas
'91 Carat, '79 Super  conv, '73 Super, "75 IHC Scout