s2004 Discovery II recently bought had three door actuators not functioning correctly, so I took one apart, to see precisely why it wasn't working. To make a long story short, I found that one of the small electric motors in actuator was worn out, having commutator section worn way down--junk. So I bought and installed new actuators in three doors, one rear, and both front, and they now work perfectly. During this work, I noticed one of the small nylon, plastic, wheels, rollers, in the window regulator, driver's side door, was broken, and I recalled seeing that Falconworks of Arizona sells replacement wheels, rollers, made from aluminum, far better than original nylon, for this application, but they cost around $20 or more each. Front windows have three wheels, each side, and rear windows have two each side. So, I took my regulator apart, thinking that I would change out all three wheels, rather than only the one broken one, since they are not all that much fun to take apart and reassemble, and they obviously do break. Using one of the "good" nylon wheels for dimensions, I turned new wheels on my precision lathe, from same aluminum material that Falconworks makes theirs from. After installing them, I was a little concerned that they may not function correctly, because they were a little tighter than I would have liked, but it is now all back together, nicely greased, and the window rolls up/down as smoothly as silk, so they worked beautifully. Enough aluminum rod to make wheels for all windows on Rover, which I will eventually do, cost me exactly $13.

 

Post pictures of all this great progress!
Thanks for the hints and the update.
Cool on the lathe.

 

Did you replace just the motors in the actuator, or the entire unit?

I ended up buying one of the FalconWerks wheels and copied it using a lathe. Pretty easy to do and much less expensive than paying over $200 to replace all the wheels. And I made extras just in case!

 

Anybody interested in selling some of these extras wheels?

 

Sorry, folks, but have no cameras of any kind; hate cameras of all kinds, so unable/unwilling to post pictures. I am 70 years old; lucky to be running computer and keeping up with maintenance on Rover, so you will have to visualize what I posted.

 

How many do you need? I think 8 will do every window regulator.

 

I replaced the whole actuator in each door I did, three doors, with new actuators. No way am I going to install used ones, since they are no fun taking apart and putting back together. After taking apart that first one I mentioned, finding the motor seriously worn out, I learned that there is no way any human could possibly take a Discovery series II actuator apart, replace a motor or something else internally, and put that actuator back together. If you doubt me, take one apart and you will see what I mean.

 

Nope, Discovery IIs have three wheels in each front door, and two in each back side doors, for a total of 10!