Window Regulator - Inoperative
NO.: 23-29-93GROUP: Body
EFFECTIVE DATE: Jun 4, 1993
SUBJECT:
Drum And Cable Window Regulator Retrofit Procedure
MODELS:
1989-1990 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country
1984-1988 (S) Caravan/Grand Caravan/Voyager/Grand Voyager
SYMPTOM/CONDITION:
The window regulator may become inoperative due to the flex track portion of the window regulator being damaged.
DIAGNOSIS:
Inspect the flex track portion of the window regulator for damage or mis-positioning.
PARTS REQUIRED:
Each Manual Regulator Package Consists of:
1 Window Regulator
1 Screw & Washer Assembly, Upper Regulator to Door Attachment
6 Screw, Regulator to Door Attachment
1 Template, Window Regulator Retrofit
1 Instruction Sheet
REPAIR PROCEDURE:
This bulletin involves replacing flex track style window regulator(s) with drum and cable style window regulator(s).
NOTE:
WHEN REMOVING THE RIVETS ATTACHING THE REGULATOR TO THE DOOR, DO NOT USE A DRILL BIT LARGER THAN 1/4 IN.
1. Using the appropriate steps of the procedure outlined in section 23 of the applicable service manual, remove the damaged window regulator(s). Save the hardware attaching the glass to the regulator for use at reassembly.
2. Remove all debris from inside the door shell.
3. Use the reference holes of the template (P/N K4746908) to properly position the template on the front door(s) inner panel then tape the template in place. Refer to Figure 1.
4. Center punch and drill, 7.9 mm (5/16 in.) holes identified with an * (asterisk) on the template. Four are for the regulator cable guide bar and three are for the motor attachment (if the vehicle is equipped with electric windows).
NOTE:
IN THE NEXT STEP, BE CAREFUL NOT TO TWIST THE CABLES OF THE WINDOW REGULATOR ASSEMBLY.
5. Position the new drum and cable window regulator in the door and attach the cable guide bar with 5 screws (4 - P/N 6501682 and 1 - P/N 6100557) which is used at the up stop position. The top screw should be left loose for now and tightened when making the final adjustment to the up-stop in step 10.
6. A) For electric regulator equipped vehicles, attach the motor to the inner door panel using 3 nut & washer assemblies (P/N 6100048).
B) For manual regulator equipped vehicles, attach the manual drive assembly to the inner door panel with 2 screws (P/N 6501682).
7. Using the original hardware, attach the glass to the regulator.
8. If the vehicle is electric regulator equipped, locate the wiring harness extension package (P/N K4746909). Determine which insulator in the package needs to be installed to the door harness end of the wiring harness extension (black for 1988 and prior, red for 1989 and 1990). Referring to Figure 2 for proper wire to insulator orientation, assemble the appropriate insulator to the wiring harness extension. If the red insulator is used, the wedge must be installed in the terminal end of the insulator and xmas tree fastener must be inserted into the slot on the side of the red insulator.
9. Install the wiring harness extension (P/N K4746909). Use the xmas tree fasteners of the insulators to secure the harness to the door, refer to Figure 3. At the forward attachment point, the insulator must be installed so it is inside the door cavity. At mid-door attachment, install the insulator so it is outside the door cavity. Bend the tab back into the door so the insulator becomes flush to slightly underflush with the inner door panel.
10. Verify the proper operation of the window. Adjust as necessary. Tighten the upstop screw.
11. Reinstall the door trim.
POLICY: Information Only
TIME ALLOWANCE:
Labor Operation No. 23-34-10-96 Power Window Regulator 1.0 Hrs.
23-34-10-97 Manual Window Regulator 0.9 Hrs.
FAILURE CODE: 27 - Damaged