Thread: DYI Window Regulator Runner Repair with photos

'I said I wasn't going to pay $100 plus for a new window regulator so I set about to create a new runner, and it works just fine.

Materials/tools needed:
A min of 6mm thick plastic ( ie: a cheap kitchen cutting board) or scrap of Teflon.
1 x Metric 6 x 200mm bolt.and nut.
I x Nyloc bolt to suit.
Some Loctite.
Router table
Saw table
Drill.
Angle Grinder.
Sand paper.
Ruler.

Step 1: Route the piece of plastic to dimensions.


Step 2: Grind the head of the Bolt head flat, leaving enough head to give strength to head area.

Step 3: Centre drill the runner guide to accomodate the bolt shank and counter sink the bottom to allow bolt head to now sit just below flush with base.


Step 4: Fit bolt and screw nut tight to runner guide top, use some Loctite to secure it. Fit the runner guide to window glass channel and check for freedom of movement.


Step 5: Use andle grinder and carefully grind away the old broken Runner guide from the Regulator arm.

Step 6: Fit your new runner guide to the regulator arm. Fit nylock nut and tighten till there is still enough play for the runner guide to spin on the regulator arm. Cut off any excess bolt thread that protrudes.

Step 7: Fit the runner guide to window channel, apply liberal grease and refit to vehicle.

All up cost for this repair is very little.

I had the same problem in my disco too... in the end it was on the passenger side so I just screwed a piece of timber in under the window to hold it up... didn't cost me a thing [img]style_emoticons/<#EMO_DIR#>/smile.gif[/img] stayed like that for 6 months.

Actually in the end I had to replaced it because the arm had bent in two spots [img]style_emoticons/<#EMO_DIR#>/sad.gif[/img] But I do believe it was because it came off the runner.

Matt.