Thread: Cheap $4 fix for Discovery 1 or 2 window regulators - replacing plastic rollers

Hi Folks

Well I got fed up with the occasional broken plastic roller within the Disco window regulators which usually means sourcing a whole assembly either new or lately second hand.

I selected this $4 dollar steel ball bearing part (Bunnings) and the trick is to grind both sides on a bench grinder to achieve 5.1mm. Now this part is surprisingly strong and very capable of taking grinding. I used a chainsaw grinder and with fingers allowing the ball bearing wheel to turn taking time to allow to cool and finish off on both sides. There is plenty of steel to work with to achieve the reduction from 6mm and the white outer roller is very tough so will not melt at all. When finished just clean up the bearing and lube. I didn't use any fuels to clean in case reaction from the white outer.

I replaced mine in car by just grinding the back end to remove the old press stud.

Two issues, (1) the track at the end it crimped over a tad so just open up carefully with pliers. (2) the nylock bolt will only foul in the upper most almost closed position (last 1.5 inch of the window) but you can easily see the middle skin through a large inspection hole and the bolt head so I just did the screwdriver bending it inwards to cater and your all done. With mine this is the rear roller for the front driver's door but others will possibly need the regulator removed. If this is the case, study the clearance path first given you have a bolt head to deal with and grind down a tad.

The only difficult part is you need needle nose pliers to hold the cylinder shaft whilst doing up the nyloc bolt. I should have ground two flat edges to hand a small spanner here.

This fix applies to all Discos 1 and 2 and possibly Defenders.

Currently discos just use plastic and you can see most of this replacement is a full caged bearing here. If doing a others you just need to check clearances and modify but should not be a drama.

The best part is you will never have to replace again given the strength of this bearing against the original.

Hi, I had to fix the window regulator rollers as these as seemed to be falling apart now. I put together a simply fix of a TPU printable wheel and a slider (haven't tested the slider). They are flexible enough to just pop on over the existing stud but ridged enough to work well (need to be forced off with long nose pliers to remove). I used form ultra TPU which is very durable, grease resistant. No need to take anything apart just pull the door card bend slider channel end open remove old broken one and pop on new. link Discovery 1 Window Regulator Slider Roller by 12v1 - Thingiverse