Hi all,

I've become aware of the problem with our window regulators breaking all-too-often. Mine broke this past Thursday. After reading a few threads and talking to the service department at my local dealer, it is obvious there is a flaw somewhere in the design of this component. One only needs a quick look at the failed parts to come to the conclusion that the plastic (nylon, perhaps) used to manufacture the pulley wheels and track slides is too soft. Also interesting to note -- my service department representative mentioned many failures occur during the Winter months. This further leads me to believe the plastic used in this component's manufacture is of cheap quality. A good plastic, especially if glass-reinforced plastic (GRP), would be much stronger.

I am interested in discussing this topic to determine the direct cause of failure in our regulators. I cannot tell from mine alone, as not only is one of the track slides broken, but the drive pulley is all chewed up, with the cables unwound. If the cables were to come off the drive pulley's grooves and become stuck, or otherwise cause slack in one cable resulting in too much load on another, I believe this could cause the motor to pull a cable end out of a slider, resulting in its breakage.

On the other hand, if one of the sliders were to be the point of failure, then a cable would have no tension to keep it tracked on the drive pulley. As I, and perhaps most people, had pressed the window switch to hear the motor turning with no window movement, the drive pulley could become damaged after component failure.

If we compile all the information we can on this issue, then write both Ford, and the component manufacturer, perhaps an improved product can be designed so we do not have to deal with repeat failures. I have one post following.

Maybe not this specific thread, but I think we need a sticky on this topic (links to the DIY repair, sources for parts). I have a feeling this next Winter may bring many failures, as the units are getting older.

 

Here is a shot of the failed slider. The one that broke on me was the rearmost slider on the driver's window. In the background is the cable end that pulled out of the damaged retaining slot.



Here is another shot.



Here is a shot of the drive pulley, damaged, with cables de-tracked.



This is a shot of the two sliders from the failed regulator. They should be symmetrical. The one on the right is the broken slider. Note the two areas of damage on it. In the middle of the left slider is supposed to be a tab, but that broke off due to me taking it off the track with a screwdriver. I will note, however, that it broke way too easily. This plastic is soft, yet brittle. Very cheap quality, in my opinion.

 

My front passanger regulator failed in the heat of this past Texas summer. The window is being held up by a pair of small vise grips. I am afraid to use the other windows because of all the failures I have read about here. There definitely needs to be something done about this problem because dropping 300 bucks every year on window regulators is a joke.

 

All of Ford's cable regulators in all their vehicle lines are junk. Always have been, always will be.

 

My wife has a 2001 Audi A4 Quattro.
All four window regulators have been replaced, and we have another making the "soon to die" clicking sound. The parts are about $185 per window. Dealer charged a grand total of $645 for one door. I wish I would have had the time to repair the first one. I have done the other three and will soon replace the driver's front, dealer replaced this one two years ago.

Anyrate, same issue as described here. Extremely brittle plastic parts that attach the cables to the window regulators.

 

One broken, one soon to break. 50K miles, 2.5 years old.

 

My driverside broke today.

How hard are they to fix yourself and where do you get the parts?
Thank you

 

Cliff'

Send me your e-mail address, I'll send you the pdf file fromt my Ford Service manual for changing the part.

 

mine broke 2 weeks ago, 300 to fix at the dealer. I feel the same way I am worried to use the fearing they will break again while I am away leaving my truck wide open

 

WTF is the deal with the plastic anyway? Why not just connect the cable to a metal component instead of plastic? I mean, they use metal all the way up to the point where the cable attaches, then plastic. WTF is that all about???? I swear, sometimes I think these designers need to just get a swift kick in the nads...

 

Thanks but got it fixed.
It was suppose to rain a lot today so I spazzzzed.
$275 and no rain I got it back.

Sometimes I wish I had a 1980 Bronco!!

 

If you don't mind, please send me the file. I pm'd my email address to you. I have two broken regulators on my 04 Screw, unfortunately both within one week.

Argg, I can't PM you since I have less than 100 posts. My email is flopez5 at stx dot rr dot com.

Thanks!

 

Well mine might be in the verge of failing. My driver window won't goup if it's all the way down I have to "help" it up to the half way point and then goes up fine.Goes down no problem though

 

So far the ones in my F150 are holding up fine. The ones in my Ranger were crap though. The windows would start jumping, then they would stop working. Had to replace those a few times.

 

Is there a cushion or something that helps keep the window secure, keeping it from rocking front to back? I noticed on our exped. that the window seemed to drag, like it had too much resistance on it(after having the glass changed due to breakin). Had the glass guy pull the panel and adjust something that freed up the window. Went up and down a lot quicker and smoother. I wonder if this has anything to do with these plastic pieces failing(too much resistance that breaks them).