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Old 08-21-2009, 09:09 PM   #58
bond007
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Join Date: Aug 2008
Location: Durham, NC
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Follow-up to my original post:
I ordered a regulator mechanism off eBay, ~$60. It came with the necessary hardware (bolts and two new plastic sliders and metal clips). The regulator I removed was pretty bent up. I don't think that they can be straightened too many times and for the amount of pain it is, it's probably cheaper to replace it if the first repair attempt doesn't hold up. I installed it and the window still popped out of track.

I pulled the other side apart (which had yet to break) to re-grease it and compare. Moving the broken window up and down the guide, it felt like it was binding and the rear guide felt like the culprit. I re-greased the side that was still functional and put it back together.

I pulled the rear window guide out of the broken door, removed the felt, cleaned it as well the glue side and the metal channel and then re-glued it with the proper glue, 3M super weatherstrip and gasket adhesive (http://www.autobarn.net/3msupweatgas.html).

The mechanism seems to be working fine now. I am still skeptical, as the prior time, it behaved similarly. I will give it a couple of weeks of abuse before I pronounce it fully cured. Meanwhile, I am repairing the door panels, yet again.
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