Power Window Popped: What likely happened?

[Tom and Vipers]

96 GTS 90k miles.

Window down, went to close it, popped, window now down in door.

Seems like motor is trying to work.

I will be getting into this within 24 hours, however, I will have access to the car only until 10/4 which is only 10 days from now, and fewer business days.

I have heard the regulator is NLA and there is some kind of "line" that breaks. Is this the plastic "chain" used everywhere in regulators these days?

Anyhow, I will be scrambling to get this down given this is a parts sourcing problem most likely, so any advice would be appreciated.

Thanks
Tom

 

[99 R/T 10]

There have been a few threads on this problem lately, Dave is usually good at finding them. Call Chuck Tator, 914-763-3136.

 

[uvbnbit]

What??? Michael, don't tell me you don't have a window regulator layin' around somewhere. Could it be that someone needs something that you don't have?
-Chip

 

[99 R/T 10]

Actually I do , but I am keeping it for myself. Not if, but when these widows fail

 

[Tom and Vipers]

Well, if a part had to break, what broke is not that critical.

I opened the door up and found the window clip laying in the bottom.

Then I saw that the white plastic shuttle was stuck at the top of the track. (The Clip holds the window pin in the shuttle which raises and lowers the window.)

I got the shuttle back onto the track and the regulator works perfectly.\

Only problem: the shuttle has legs at each end which reach around the track. The top leg broke off.

Soooooo..... window will probably work OK if not taken all the way up.

But solution might be to fabricate another shuttle out of aluminum or a fiber reinforced plastic.

If this is a common failure, maybe I could fab and sell them.

It might also be the same shuttle used is other Chrysler cars - a glass replacement tech with a good memory could answer that question once he saw what one looked like. Who knows, there might even be a generic repair part sold thru glass repair guys.

I was glad to see they used aircraft cable instead of that plastic strap junk.

So that is it for now.

 

[99 R/T 10]

Apparently, it has been tried before. So far I haven't seen any on the market, so I am guessing none worked. But if you can make some, I will order 2 right now.

 

[Tom and Vipers]

It is my strong opinion, that a simple mod might massively increase window regulator shuttle.

First, a little failure analysis discussion:

PHASE 1:

It looks like the top leg of the shuttle breaks because it always bangs into the bent track tang which limits the upward travel of the shuttle.

PHASE 2:

Once the leg breaks, the next thing which limits shuttle travel is the window itself.

Now the window pin in the shuttle starts beating downward into the shuttle.

Eventually, the top part of the shuttle clip retainer flange feature breaks off.

Once this is gone, the only part of the pin bearing in the shuttle is the tiny, 1/16" of pin between its clip groove and taper.

This 1/16" engagement in the shuttle is inadequate and the pin pops out - maybe taking the flange feature with it all in one act.

Now the window is dead in the track.

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Immediate service for working regulators: The track tang that breaks the shuttle leg can be bent the other way so the tang impacts the shuttle body!!!

In this case, the top shuttle limit feature will never be lost which strongly suggests that PHASE 2 never occurs.
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What is interesting is that even if the shuttle has both parts broken, it might be possible to swap shuttles between the doors and do the tang reversal mod.

When reversed, all the part loadings are on "opposite" features which are still like new in a high mileage car.
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Is the shuttle the part that fails 90% of the time?

 

[JonB]

Since the motor is trying, I strongly suspect the simple connector bracket / shuttle clip.
Quite a few guys on here found this the case, and PartsRack has the fix! NOT AVAIL THRU DODGE, except as a regulator assy, But PartsRack has em alone for $95.

If you buy it and Im wrong , you get 100% refund.... I hope some 'satisfied customer' on this item might even pop in here....

 

[Tom and Vipers]

Code Name: Project Lunacy
Phase: I

Phase II:

Phase III: