I have followed all of the instructions on this thread: https://landroverforums.com/forum/di...r-34345/page3/

But I just cannot get all of the bolts to line up on reinstall. I have the window bolted up to the long arm and just got the small arm to line up, but now the motor is way out of whack and pulled the plug out in the process.

What am I doing wrong? Seems like the install should go about the same as the removal but the motor wants to climb up out of reach...

 

Figured it out - make sure the window is 100% up before the install. I got one bolt in and then turned the Disco on and pressed up on the window button to get the other holes to line up. Whew.

 

ReAustinIX, jh. and many others - thanks for sharing instructions on how to fix the window regulators & motors. I followed on instructions your threads & that helped a lot.

However,I am struggling to figure out how to stop the regulator gears from shooting past the motor gears when the window is rolled all the way down -as this causes the window to get stuck. I would have to force the gears back in place and the window is rolled up & down fine - just bearing in mind not to roll it all the way down. Unfortunately, my wife forgets not to roll the window all the down and she gets it stuck. The motor works fine in both directions.

Does anyone know how to solve this problem?

 

Is the Window regulator clip still attached?

 

Sometime this coming week, I will check to see if the regulator clip is still attached and let you know my findings.

 

The regulator clip is attached. I replaced it, though, with a new one but that did not fix the problem. It appears to me that the regulator clip keeps the window securely attached to the regulator but does not play a part in stopping the window before the regulator gears shoot past the motor gears.
I took some pics of the regulator clip and gears which I will post on Sunday.
I am also thinking of comparing the driver's side window components, which works fine, with the passenger side that this problem to see if I can spot any difference which could be causing the regulator gears to shoot past motor gears & I will post the pics for ease of reference.
I tried to unplug the motor after closing the window so no one would open it but I failed to do so because the plug is out of reach. So for the time being, I covered the button for opening & closing the passenger window with a thick layer of tape as a reminder to my wife not to open the window. It's doing the job but it's unsightly.
Once again, thank you all for the tips & tricks that make it very easy to work on windows. After doing uninstalling my regulator 3 times I am no longer intimidated by this job.

 

The regulator clip attaches at the bottom of the regulator arm and keeps the regulator from going below the intended depth. It is not the round rollers inside the regulator rails.

I shot a couple of pictures of mine for better clarity. See attached.

 

Oooh, wow! Compared to the how your clips are attached to the regulator, the old regulator clip on my window was up-side-down such that the section of your clip that is hanging below your regulator was leaning against the glass. So, when I replaced it I installed it the same way.
I am going to turn it up side down so it hangs below the regulator rail and act as a window stopper.
Thanks a bunch. That clears my confusion.

 

I flipped the regulator clip so it is hangs below the regulator arm/bottom rail and here is what I observed,
(1) it appears the clip does not install/fit well on the regulator rail/horizontal arm when flipped to hang below the bottom regulator rail.
(2) that solved the problem briefly because after 2 to 3 window openings the motor overpowered the regulator clip and folded it into two halves and I was back to square one - the regulator gears shot past the motor teeth when the clip was folded in two halves.

Some friends said, when rolling down the window, the window is stopped by a little hump-like thing on the regulator/motor. Here are 3 pics that show the regulator gears moving in the direction for opening the window, regulator gears stopper (hump-like thing) & gears past the stopper and motor teeth.

Opening window
https://lh6.googleusercontent.com/-Y...or%20teeth.jpg

Regulator gears arm stopper
https://lh3.googleusercontent.com/-c...%20stopper.jpg

Regulator gears past stopper & motor teeth
https://lh4.googleusercontent.com/--...or%20teeth.jpg

Friends also suggested welding the stopper (hump-like thing) to replace the worn out metal so the gears would get stopped. I skipped this suggestion, even though it sounds very reasonable and less costly, due to lack of tools. I will follow this suggestion if the one I picked gives up on me.

They also suggested installing a bolt in the hole that is on the regulator gears arm - above the spot that should be stopped by the regulator gears stopper. That would require 1/4 threads inside the hole, they said, and a bolt. I tried that without threading the hole as shown in the pics below.
https://lh4.googleusercontent.com/-_...tion%202-a.jpg
https://lh5.googleusercontent.com/-N...tion%202-b.jpg

This worked to stop the regulator gears but the Disco window motor seem so powerful that the regulator gears arm was getting a little twisted/raised just before the motor stops running as the motor tried to pull the nut/bolt over the housing for the motor. So I abandoned this idea because I don't want to cause more damage to the regulator or motor. I figured that works well if the bolt does come out on the other end so the regulator arm is stopped by bolt head when it gets in contact with the cover that is where the regulator gears get in contact with the motor teeth.

So, I opted for this solution (explained by way of pics).
https://lh6.googleusercontent.com/-O...tion%203-a.jpg
https://lh4.googleusercontent.com/-6...tion%203-b.jpg
https://lh6.googleusercontent.com/-z...tion%203-c.jpg
https://lh6.googleusercontent.com/-L...tion%203-d.jpg
https://lh6.googleusercontent.com/-X...tion%203-e.jpg
https://lh3.googleusercontent.com/-s...tion%203-f.jpg
https://lh3.googleusercontent.com/-1...tion%203-g.jpg
https://lh3.googleusercontent.com/-N...tion%203-h.jpg

This was an easy and cheap fix and it works. But my observation is, it appears some force/pressure from the motor (before it shuts off) is also absorbed by the regulator arm. I have indicated this arm and spot that appears to absorb the force/pressure with an arrow in the last pic above. I doubt that my window will shutter someday.
because of this.

 

Your clip must of been old an brittle. I have never had an issue with mine. But kudos for fingering out a fix!