Window regulator pulley fix (of sorts)
 

Hi I have read countless discussions on the window reg. failure. Mine happened yesterday. Motor works but window dropped down. After removing the door assembly per the fantastic instructions here and Youtube, my cable was intact. I removed the motor and pulley and found that the 3 plastic pins that engage with the motor were broken, so the motor just spun freely.

I took out the 3 plastic broken nibs that were in the rubber star shaped cog on the motor side. This left 3 open spaces. I found 3 small screws that had flush heads and placed them under the rubber cog so the screw tips were protruding upwards. I drilled 3 holes into the master pulley (where the tabs broke off) so that the screw tips fit in.
Re-assembled into bracket (nice snug fit), presto bing magic, time for Guinness.
Now I have new engagement tabs for the motor and pulley.

Reassembled and VOILA.

Probably not a permanent fix but the screws hold very well. Used some lithium grease to make sure and lubed the tracks and under the screw heads to make sure.

Fix. Cost.... 2 hours my time and found some screws in my tool chest.

I know... I Know... pics would have been great but I didn't think it would work....

Any questions pm or email me.