Hi, Rolled up window and heard a snap. Suddenly the window went down by itself. Cant raise it any more but I can still hear the motor if I turn it up or down. Anybody had this problem before? Is that fixable without ordering parts? Or, do I need to order the part before opening the side panel? Thanks.

BTW is it easy to open the side panel?

 

There is a little plasitc roller in the regulator that has broken. You can either replace the whole regulator with new or used, or buy a metal roller to replace, or take the roller that snapped and epoxy it back together.

I epoxied mine and filed back to shape. Been holding well for 3 years now... There is a place with metal rollers in phoenix...falconworks, I think..

 

actually I think they are down in Tucson, but yes falconworks is the place.

 

It "may" not be the roller, not uncommon for the D2 to "shear" the 3 spot welds on the regulator which connect the arc driven by the motor, simple enough fix, either reweld or use solid rivets.

 

Thanks guys - I checked the link and saw those rollers. I will open the trim tomorrow and see what went wrong. Could be the roller or the weld snapped. The 2 metal rollers cost almost like the regulator assembly. A foot of 1" 6061-T6 aluminum rod is about $4.00 plus a couple of washers. Not sure yet until I see it. Or, coldweld epoxy like okdiscoguy did. Or epoxy, sandwich 2 size pieces of 6061-T6 rod. I'll check Sears hardware also, they have a new hard to find items here now. Thanks again.

 

The 3 spot welds and lower plastic roller cracked off on my regulator. After about 2/3 hours and dremeling I got it all back together. I used 3 bolts, drilled out the 3 spot welds and red loktited them back on. I also cut a slot in the lower rail and opted for 2 quaters epoxied together and drilled with a 1\4" hole thru them. A bolt and washer hold them on the pin. #2 Lucus tacky red grease was used to lube the rails and gear motor . I pretty much did what Josh did in this link. My windows works well now. I still may order a spare regulator to have on hand, if my fix dies.

http://picasaweb.google.com/jycsalas...57229531592130

 

Thanks again. I saw the loose part where the 3 spot weld snapped. I bought some stainless steel bolt with tapered head and lock nuts with plastic and drilled through the 2 plates. I made a counter sink on the other side where the slide will touch the guides. Too bad, I have no idea how the part looked like at first and installed the geared plate reversed and can only raise the window half way. I drilled the middle hole first and install the assembly, connected it to the power and made sure that the installation glides smooth then tighten it before adding the additional holes.
Its working very smooth now. I'll do the other side tomorrow before it happens and I know it will happen again. This time the fix is much better and pobably more durable than the original spot weld. HERE are the PICTURES BELOW.
1) Spot weld snapped.
2) Lock nuts in place.
3) Stainless steel tapered head bolts.
Pictures from my junk phone. Sorry Blurry!

 

good job! Blurry pics are better than none. Hopefully this will help someone else!