Thread: Window mechanism gear sheared off

Thought I would share this incase it helps someone else out.

Late last year, the day before heading off the The Falls Festival for New Years Eve, the passenger side window fell down. Removing the door trim (instructions are contained in Rave) I found the gear that is moved by the electric motor had separated from the mechanism:





As you can see the gear is held on by three spot welds.

Needing to have the vehicle on the road the next day and securable at the festival, I removed the complete frame and window glass and mechanism.

I drilled out the three holes to 4.5mm, and fitted three 4mm stainless steel tapered head machined screws and nylock nuts. Drill tapered holes on the gear side (a 7mm drill bit worked for me).
Using the tapered head machine screws solved clearance issues of the gear rotating past the electric motor and there was enough room in the recess of the mechanism for the nylock nuts not to cause any clearance issues.

Forgot to take any more pictures as was in a rush to get the car operational and packed!

Mine got drilled and migged about two weeks ago.