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86scotty
Samba Member
Joined: July 25, 2013
Posts: 223
Location: Tennessee
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 Posted: Sun Feb 05, 2017 7:48 pm Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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Dave, you didn't really say how much of a difference it made. Night and day? Worth it over just lubing what you can see or otherwise?
My to-do list is long. This looks like an entire 12 pack worth of work. 
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86 Vanagon Westfalia 87k
1998 Ford E350 4x4 camper build
Vans flip flops |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32598
Location: Reading Pennsylvania
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86scotty
Samba Member
Joined: July 25, 2013
Posts: 223
Location: Tennessee
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| Posted: Sun Feb 05, 2017 10:01 pm Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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Thanks!
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86 Vanagon Westfalia 87k
1998 Ford E350 4x4 camper build
Vans flip flops |
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WLD*WSTY
Samba Member
Joined: November 04, 2009
Posts: 438
Location: Arizona
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| Posted: Sun Feb 05, 2017 10:40 pm Post subject: Re: Window regulator cleaning and lubrication |
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| Chuey wrote: |
| Recently, the passenger door started making a pretty loud clicking (ratcheting) type sound at the top of the travel. That is, when the window is being raised or lowered, near the top. |
A late reply, but I just had the same problem occur. The plastic extension tube had developed a small kink about three inches from the outer end. A heat gun took the kink out and the ratcheting disappeared.
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'82 SyncroWesty, the first ever conversion.'06 Subaru 2.5L |
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Gizmoman
Samba Member
Joined: September 10, 2011
Posts: 1554
Location: Nevada
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| Posted: Sat Apr 14, 2018 4:07 pm Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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Passenger door regulator has popped out of the track for the second time in a month - time to go deeper.
Following Dave's excellent instructions, I have the regulator out. The issue appears to be the square block is missing the tiny guides on one side. I'm also missing one of the plastic guides that runs along the rail. I believe I can make both of these items and possibly a bit heartier than the stock ones.
My issue right now is trying to remove the square plastic block.
In Dave's instructions, he mentions some tabs that need to be squeezed together.
. I can't seem to squeeze them together enough or I don't understand how it works. There is a slot between two tabs but it's not wide enough to allow much squeezing.
Any tips?
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82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th
Oversize spare carrier - stock location (no longer for sale). |
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0to60in6min
Samba Member
Joined: November 27, 2006
Posts: 3416
Location: OR & CA (Oregon/California)
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| Posted: Sat Apr 14, 2018 4:14 pm Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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| I'd put some sound deadener (i.e FatMat) on the door panel before putting back the window regulator. |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32598
Location: Reading Pennsylvania
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Gizmoman
Samba Member
Joined: September 10, 2011
Posts: 1554
Location: Nevada
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| Posted: Sun Apr 15, 2018 4:53 am Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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| djkeev wrote: |
I circled the tabs.
I was lucky, didn't have to remove the square block.
As I remember,
It seems like a split pin.
Clean it out really well and using needle nose pliers, pinch them together.
This should allow the metal plate and nylon block to come off.
Dave |
Thanks Dave. I have studied the design carefully with a magnifying lens after cleaning it with brake cleaner. My van is an 82 and may be different than later years. The metal portion that holds the plastic block is entirely round and has no flat spots on the sides as you show in your photo.
The design is really pretty ingenious. Imagine a small rectangular plate with three long slots in the center. These slots are set to the pitch and lead angle of the spring (screw). The plate gets formed around the inner cable bringing the two ends together to form a double tab. The plastic guide block is installed over this tab then the metal boss - which has a slot for the tab. This assembly is then inserted into a fixture and set using a conical punch to deform the two tabs away from each other and into a tapered recess in the metal boss.
I tried to un-deform the punched tabs, but as you might guess, the metal is quite hard and wouldn't budge. The next move would be to drill or Dremmel out the deformed metal - possibly a quick tack and quench would hold it after the new plastic block was installed. Again, different years may have different ways to attach this. I can't imagine GW would make a repair kit unless there were units that can be disassembled, but I can say with some certainty that this unit was never intended to come apart.
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82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th
Oversize spare carrier - stock location (no longer for sale). |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32598
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32598
Location: Reading Pennsylvania
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Gizmoman
Samba Member
Joined: September 10, 2011
Posts: 1554
Location: Nevada
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| Posted: Sun Apr 15, 2018 5:14 am Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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Dave, my lift is manual - never said anything about it being electric.
I'd post some photos (and may yet) but it's pretty much junk now. I followed GW's PDF instructions but should have taken more care before I tried unscrewing it from the cable/spring assembly.
At the end of the cable, the spring appears to be either swedged or welded to the end of the cable. This blob interrupts the threads significantly and if you force the nut (block) over this blob, you're going to ruin it.
I'm not saying there may be models where this is not the case, just saying it is the case on mine which is an 82.
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82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th
Oversize spare carrier - stock location (no longer for sale). |
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Gizmoman
Samba Member
Joined: September 10, 2011
Posts: 1554
Location: Nevada
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| Posted: Sun Apr 15, 2018 5:53 am Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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Here are a few pics. . .
The "blob" at the end was originally much larger than it shows in the pics. I used a tiny grinder to try and form a continuous thread so I could re-install the nut which I deformed during the removal. As you can see in the photos as well - the nut was too far gone to re-use. I tried to re-form the three loops and the center one broke - this stuff is quite hard.
Had I taken more care before I removed the nut, this may have worked. There is no mention of this in the GW PDF instructions should one decide to buy their repair kit. Not a slam on GW - just a heads-up for anyone attempting the fix.
The last photo shows my attempts to un-deform the tabs to allow the steel boss to slide off - the metal is likely spring steel and does not respond well to a punch or screwdriver.
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82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th
Oversize spare carrier - stock location (no longer for sale). |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32598
Location: Reading Pennsylvania
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Gizmoman
Samba Member
Joined: September 10, 2011
Posts: 1554
Location: Nevada
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| Posted: Sun Apr 15, 2018 6:33 am Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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As it was ruined anyway, here's a shot of what the nut assembly looks like before it is formed and swedged.
Obviously, there's a missing rib in the center but hopefully you get the idea.
Also, if you notice the width of the slot in the round bit is just enough for the sheet metal tabs to fit through. Once it gets swedged at the factory, it's not going to come out easily if at all.
I was able to get this one out because the plastic block was not in the way and I was able to put it in a vise and hammer a screwdriver through the slot.
Also obvious is it's not spring steel - it is pretty tough though.
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82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th
Oversize spare carrier - stock location (no longer for sale). |
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nilza
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Joined: May 21, 2007
Posts: 342
Location: brisbane australia
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Gizmoman
Samba Member
Joined: September 10, 2011
Posts: 1554
Location: Nevada
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| Posted: Fri May 18, 2018 4:31 am Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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Thanks for the link. While mine is fixed and will hopefully last till I'm no longer available, it adds to the thread's help factor.
3D printing and NLA parts - a perfect combination.
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82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th
Oversize spare carrier - stock location (no longer for sale). |
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Jacebc
Samba Member
Joined: June 14, 2019
Posts: 8
Location: Bainbridge Island
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| Posted: Sat Aug 03, 2019 4:51 pm Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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Thank you for this super helpful guide. My repair was going well until I accidentally destroyed the small metal oval thingee that supports the window rail. 
Any ideas of who would stock that part? Or do I need to get the entire manual regulator unit for a 1986 Vanagon Westy drivers side?
Bonus question: my window tint was scratched when the regulator failed. Can the window be retinues without removing the glass?
Thanks so much! |
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bajaleo 
Samba Member
Joined: March 21, 2009
Posts: 211
Location: San Juan Capistrano, CA
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| Posted: Mon Oct 12, 2020 7:24 am Post subject: Re: Window regulator cleaning and lubrication (Manual) |
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I'm hoping someone can help me. My van came back from the paint shop missing these parts. Driver's side door (US).
Does anyone have them laying around. Will pay money!
Thanks, Leo
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Leo in San Juan Capistrano
1984 Wolfie Westy, Subaru EJ22 powered. |
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