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E39 Rear Window Regulator Repair Kit

Instructions

Instructions for E39 rear window regulator repair kit.

Tools required:

#2 Phillips screwdriver                 Flat blade screwdriver

T20 Torx driver                                  T25 Torx driver

10MM socket and ratchet            10MM box or open end wrench

Electric drill                                          Pliers

 

The repair kit includes:

2-Aluminum repair clips               2-4-40 X ¾ flat head screws

2-4-40 Locknuts                                1-1/8 drill bit

1-1/16 hex key

 

 Email me if you have questions or problems with the installation.

It takes me about an hour to do the job on one door start to finish but I’ve had some practice, so allow yourself at least that much time to do one.

 

Please read through these instructions once before starting, it will make things easier.

 

· Remove the cover over the screw under the door handle and remove the screw using a Phillips screwdriver.

· Using the flat blade screw driver gently go around the bottom and sides of the inner door panel and pop it away from the door.

· Once it is loose push the door handle assembly through the door panel and pull the panel free from the door by lifting out and away.

· With the door panel free from the door disconnect the wires from the speaker, light at the bottom of the door, and the window switch. The easy way to get to the window switch is to remove the wad of foam filling the hole where the wire goes and push the switch out with your finger. After setting the door panel aside reconnect the window switch to the wiring and let it hang free, it will come in handy later to move the regulator when disassembling and assembling the window mechanism.

· Remove the foam door seal located under the panel. Use care not to tear this as it is what keeps water out of the car that comes in from around the window seal. New sealer may be needed when reinstalling this part to keep your floors dry.

· Remove the window wiper, the part that remained behind when the panel was removed. 

· Remove the plastic cover between the wing and main window. Use a flat blade screwdriver as shown to get it started and carefully remove it.

 

· Under the cover are 3 Phillips screws, remove them.

· Lower the glass either manually if things are broken or by using the window switch if not so that the T24 Torxs screw is reachable and remove it.

· Carefully lift and pull out slightly on the window glass and free it from the regulator.

· Gently lower it to the bottom of the door.

· On the outside of the door cover the trim with some tape to protect it from scratches. 

· Carefully pull free the rubber window track/seal from the upright between the window and the wing.

· Now for the scary part! grab hold of the window divider at the top and gently pull it away from the door and up, it may take some wiggling back and forth but it will come up past the upper trim and out of the door.

· Once that is out you can remove the glass from the door by pulling it backwards out of the front track and then sliding it up and out through the top of the door on the outside. It must be out of the front track, it’s not hard, be persistent.

· With the glass out of the door you can use the 10MM socket to remove the star looking bolt at the top of the regulator.

· Using the 10MM box end wrench loosen the bottom regulator bolt 2 turns, you don’t have to remove it.

· Using the T20 Torx driver remove the 4 screws holding in the regulator motor.

· Disconnect the power connector from the motor by pressing in the two side clips and pulling it off.

· You can now remove the regulator by lifting it out of the bottom slot, then rotate the bottom towards the back of the door and out the big hole.

· You now have the regulator out. This is what I will call the front of the regulator, the side that faces the interior of the car.

· On the backside is the part of the bracket that breaks, all of these photos are of an unbroken bracket.

· This is a shot of how it should look unbroken and how you will want to set the metal ball that is on the wire when you repair it.

· Using pliers try to bend any broken/bent pieces back into this shape so that the repair piece will fit over it and bottom out against the bracket.

 

· Once you can fit the repair part firmly in place using the drill bit supplied drill through the hole in the repair part through the regulator bracket.

· Insert the screw through the repair part and the bracket and thread on the nut. Tighten the screw with the hex key supplied. The nut should bind in the bracket, you do not need to draw the nut down fully tight and may not be able to, if the screw starts to bend that’s enough.

· Hook the regulator motor up and run the bracket to both ends to make sure that it doesn’t hit, if it does either bend the regulator ends out or file on the repair part. It shouldn’t be necessary if it is fully seated as shown in the picture above.

· Well you are done except for reassembly.

· Quick reassembly steps

· Install regulator and tighten bolts

· Install motor screws, and be sure to attach power to the motor.

· Install glass back into door

· Install metal window track and 3 Phillips screws

· Install rubber window track

· Install glass into front and rear tracks and make sure that it slides smoothly up and down by hand, then lower it onto the regulator attachment point and install the T25 screw that holds the glass to the regulator, don’t over tighten. Now’s the time to run the window up and down carefully with power to make sure everything is right, if not figure it out and make it work right. In some cars the repair part will strike the door cross member. If this happens there are several ways to correct it. You can file the edge of the repair part that is striking the cross member until it clears, shim the regulator frame out from the cross member using a small piece of wood, folded cardboard, or tire inner tube, and a method that has been used by some of my customers is simply to pull on and bend the regulator frame to get the clearance.

· Install the plastic cover over the divider between window and wing.

· Install the window wiper at the top of door.

· Install the foam door seal making sure that it is sealed to keep water out of the car.

· Install inner door panel after connecting the wiring.

· Done! Run the window up and down and smile you just saved a couple of hundred dollars!

 

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