Installing a New Power Window Motor.

Last weekend we replaced the power window motor, and let me tell you, it was quite a job.  Before getting started, make sure you have a whole afternoon to get the job done.  When attempting something like this for the first time, its important not to rush through the procedure, too many things can get screwed up.

To start, disassemble the interior fixtures on the door panel.  Unscrew the handle and the torx from the door lock (be aware that some of them are just molded plastic and are not functioning) remove the mirror adjuster.  Pry the interior door panel off the frame and check for damaged clips that will need to be replaced.  In my case, the black paneling along the top of the door was also loose, we purchased the smallest self starting screw we could find and screwed it to the panel for a more secure hold.  We also noticed the holes through which the white clips were attached were deteriorating; to fix this we glued them in place with a small amount of silicone. Finally, remove the plastic moisture shield, do not throw away.

Once that is done, we raised/lowered the window to the half-way position so that we could access the motor without the risk of damaging the glass.  It is important to be aware of the semi-circle gear that actually facilitates the raising and lowering of the window, it is under intense pressure from a strong spring, and if released improperly will act as a circular saw and can possibly cut open a hand or bust a window.

Next, we padded the bottom of the door with towels, and actually stuffed a men’s shoe into the door so as to support the window after we disconnected the motor.  We also used rubber coated clamps to hold the window up from the topside and slid a screwdriver in an already present hole just below the rear-view mirror to support the window.  Make Sure Your Window is Secure!

Then we drilled out the seven rivets holding entire system in place.  Unfortunately, we didn’t see a convenient way to remove the system, so we worked through the door.  We slid the three wheels out from the grooves and rested the contraption in the bottom of the door.  It was at this point we secured a strong metal clamp on the inside of the door so that when we removed the motor itself, the aforementioned gear would not create further issues.  If you attempt this job yourself, be VERY careful here, you do not want to make a mistake!

After the clamp was secure we cautiously removed the motor and installed the new one.  When installing the new motor, the gear in the motor has to line up with the semi-circular gear.  Rivet the motor into place with the window system.   Then, only after the motor was securely attached, we removed the clamp restraining the gear.

To secure the entire device back to its original position, we used the closets sized rivets we could find, but also used washers to make sure they were secure.  There are two holes in the motor where the rivets go through to mount it to the door, here, we glued a washer on the inside of each hole before attempting to reinstall it as it is impossible to do after it is in position.

First we slid the three wheels back into their grooves, and then lined up the holes where the rivets would be used to hold up the motor itself.  After these two rivets were put in, we manually raised/lowered the window itself to help line-up the other holes.  Make sure they all line up before inserting a rivet.  Next, we added another set of rivets and washers to the two holes in the middle, and finally a set of bolts, washers, and nuts to the final holes to the far left.

Before putting the interior door panel back in place, make sure all of your tools, leftover materials, and any residue from drilling out the original rivets are removed.  Also make sure to lube up the gears with an oil based grease and grooves that the wheels fit in with white lithium grease. Finally make sure the plastic moisture shield is glued back in place so as to protect all your hard work.  Fit the door lock mechanism and mirror adjuster back in place and reattach the door handle and hardware.

Congrats, you just finished! And as an added, bonus, if you are mildly intelligent and paid attention to the saw-like gear, you still have all your digits and a solid piece of window!

Liv.