'97-'01 Window regulator fix for $20

[gba88]

Does anyone know the BEST size cotter pin for this fix?? I had to do it on my 99, and it took some experimenting with different size/diameters to get it so that the pins weren't binding in the track. I'm gonna have to fix another pretty soon here and thought it would be good to know the best size to use. Thanks!

 

[gba88]

Does anyone know the BEST size cotter pin for this fix?? I had to do it on my 99, and it took some experimenting with different size/diameters to get it so that the pins weren't binding in the track. I'm gonna have to fix another pretty soon here and thought it would be good to know the best size to use. Thanks!

Found the following sizes used on another forum: 3/32" x 1.5", and 3/16" x 1". I'm just going to get a bunch of both and see what works best.

 

[oneilljb]

OK, I was going to try the cotter pin trick, but found the drive spring wedged in the tube. I tried to pull it out, but instead of fixing it, I managed to %@#& it up so no one else will either. The pull-a-part junk yard has a 96 with power windows. I can't find a reference in my Haynes manual and have had no luck finding it on the forum, so does anyone know if a 96 regulator will fix a 98 jeep?

 

[oneilljb]

Nevermind, it won't work.

 

[killswitch]

im using this part now, works great but my window regulator guide piping thing broke to pieces now im back at square one... ah! any ideas how to do this, i tried pvc piping but that didnt turn out well...

 

[searchingforXJ]

Anyone know if you can use the passenger side on the drivers side, or the ones from the back windows?

 

[49erRider]

I bought a kit and ended up not needing it so I'll sell for $30 shipped if anyone wants it.

 

[49erRider]

Kit is Sold

 

[bonez67]

Awesome solution to a stupid OEM design!

 

[dagr8tim]

This makes me glad I didn't upgrade to power windows when I stripped my 98 XJ.

 

[kastein]

I am no expert on the 97+ XJs (with the exception of the gas tank! :roll but I would suspect you could bolt in the window regulator from a pre-97, or maybe adapt one. Anyone know for sure? The only thing I can think of is maybe the larger window glass due to the change from a two-part window (with the vent window option at the front) to a one-part window resulted in a change in the regulator design.

 

[Markos]

Found the following sizes used on another forum: 3/32" x 1.5", and 3/16" x 1". I'm just going to get a bunch of both and see what works best.

I just did this fix tonight. 3/32" x 1.5" was in fact the best size.

Total time to do the Cotter-pin fix - 30 mins. Works like a charm. Total cost $2.99 for cotter-pin kit from autozone.

While 30 minutes may have been your personal best, I don't think that it is a realistic time to convey to everyone else. I would say expect to spend at least 1 to 1.5 hours on this job. It's not difficult, but it's not a 30 minute job. In my opinion, the estimates below are pretty aggressive, especially for someone who hasn't removed the door panel eleventy billion times.

05 min: Remove door panel and vapor barrier
03 min: Remove window bolts and tape window
05 min: Remove window regulator, 6 bolts plus worm gear clips
05 min: Bend end of regulator track and remove bracket from track
10 min: Modify bracket, including drilling rivet and cutting plastic
05 min: Identify best drill bit and drill two holes for cotter pins
05 min: Identify best cotter pins and position on worm gearbracket
05 min: Put bracket back on track, will require window switch to position drive
03 min: Bend end bracket
02 min: Reinstall window regulator, motor, and worm gear clips
05 min: Attach window and adjust glass
05 min: Install vapor barrier and door panel

 

[dagr8tim]

First time I had the door panels off of my XJ was to replace the rear door glass. I did both sides.

It took me an hour and a half to remove the tinted glass from my parts donor, remove the non tinted glass from my DD, and install the tinted glass in my DD. The donor had power windows, and no way to roll them down. So I had to remove the window motor.

I can believe that this can be done in 30 minutes if you have some basic mechanical skill.

 

[Markos]

First time I had the door panels off of my XJ was to replace the rear door glass. I did both sides.

It took me an hour and a half to remove the tinted glass from my parts donor, remove the non tinted glass from my DD, and install the tinted glass in my DD. The donor had power windows, and no way to roll them down. So I had to remove the window motor.

I can believe that this can be done in 30 minutes if you have some basic mechanical skill.

I'm not quite sure how 1.5 hours to swap glass relates to a 30 minute job to dissassemble a regulator, modify by cutting and drilling, fiting cotter pins, and reassembling.

I know that I'm splitting hairs becuase it is an hour job (perhaps 1.5 or 2 for the less mechanically inclined). I did this at 10PM though, and I'm frankly getting a little tired of BS estimates.

 

[dagr8tim]

I'm not quite sure how 1.5 hours to swap glass relates to a 30 minute job to dissassemble a regulator, modify by cutting and drilling, fiting cotter pins, and reassembling.

I know that I'm splitting hairs becuase it is an hour job (perhaps 1.5 or 2 for the less mechanically inclined). I did this at 10PM though, and I'm frankly getting a little tired of BS estimates.

I have no doubt that swapping the glass when you have to disassemble the whole power window assembly is more involved. Either way, if you are getting tired of discussing time estimates for this job, why'd you reply to the thread?

 

[Norwegian]

Dammit.. i was hoping they had a fix for the old xj's too... no such luck

 

[iwannadie]

I just did this fix tonight. 3/32" x 1.5" was in fact the best size.



While 30 minutes may have been your personal best, I don't think that it is a realistic time to convey to everyone else. I would say expect to spend at least 1 to 1.5 hours on this job. It's not difficult, but it's not a 30 minute job. In my opinion, the estimates below are pretty aggressive, especially for someone who hasn't removed the door panel eleventy billion times.

05 min: Remove door panel and vapor barrier
03 min: Remove window bolts and tape window
05 min: Remove window regulator, 6 bolts plus worm gear clips
05 min: Bend end of regulator track and remove bracket from track
10 min: Modify bracket, including drilling rivet and cutting plastic
05 min: Identify best drill bit and drill two holes for cotter pins
05 min: Identify best cotter pins and position on worm gearbracket
05 min: Put bracket back on track, will require window switch to position drive
03 min: Bend end bracket
02 min: Reinstall window regulator, motor, and worm gear clips
05 min: Attach window and adjust glass
05 min: Install vapor barrier and door panel

5 minutes to remove the door panel? It's like a few screws and pops out and the vapor barrier I didn't remove just pulled away the part I need access to.

5 minutes to bend the bracket? It's a piece of metal, I grabbed it with some vice grips and twisted and took maybe 5 seconds.

That's the problem with estimates, they are not exact but it gives you a good starting point.

 

[Markos]

5 minutes to remove the door panel? It's like a few screws and pops out and the vapor barrier I didn't remove just pulled away the part I need access to.

5 minutes to bend the bracket? It's a piece of metal, I grabbed it with some vice grips and twisted and took maybe 5 seconds.

That's the problem with estimates, they are not exact but it gives you a good starting point.

First off I said 3 minutes to bend the bracket. I don't think my estimates are out of line. In fact, using the number above it should have only taken dagr8tim 60 minutes to swap his tinted glass instead of the 1.5 hours that he stated. BTW, I 'm not getting tired of discussing estimates. I said that I'm getting tired of reading BS estimates. This is the only thread I've seen where we've actually discussed them.

 

[iwannadie]

First off I said 3 minutes to bend the bracket. I don't think my estimates are out of line. In fact, using the number above it should have only taken dagr8tim 60 minutes to swap his tinted glass instead of the 1.5 hours that he stated. BTW, I 'm not getting tired of discussing estimates. I said that I'm getting tired of reading BS estimates. This is the only thread I've seen where we've actually discussed them.

I'm just trying to point out what might take a person 30 minutes to do might take you(or me) 2 hours to do.

When I did my motor mounts recently I read people saying they did one side in 15 minutes. Well, it took me a few hours to do both sides! I didn't expect to be done in 30 minutes however knowing it was my first doing motor mounts. To do them again I could do them in 15 minutes probably. Having had my door panels off a few times like I said its a few seconds now not 5 minutes.

 

[bjoehandley]

How long have the cotter pin fixes lasted for you guys? My '98 most likely just did this tonight and outside of the cotter pin fix, the repair is not in my budget.