I got the dreaded grinding noise when lowering the driver’s side window. Here is a how-to replace the regulator. The part is a complete unit and is not Vette specific (which means you can get one online for about $50 plus shipping). The job took about 4-5 hours, could probably do it again in 2. (I was very careful to not break the trim or glass!)
1. Lower the window
2. Remove the trim bezel around the door handle
3. Remove the small oval trim panel below that
4. Remove the two Torx-30 screws inside the small oval panel
5. Remove the entire door panel. There are six white fasteners. There is a special tool for this, but a screwdriver and putty knife works OK—just be careful not to break them, then lift the door panel up
6. Disconnect and remove the stereo speaker (OEM screws are 9/32)
7. Remove the large black rain shield and two small ones—use a putty knife and save the covers for re-use. Mine was pretty fragile and I had to spend about an hour repairing it with black tape and RTV.
8. Remove the two square rubber plugs on the bottom of the door
9. Loosen the two 13mm bolts on the lower window bracket, remove the window from the top—it might be stuck to the rubber brackets, just gently peel away the rubber.
10. Use a sharpie to mark the position of each regulator bolt to help install the new unit in the same place; this will help speed up aligning the new one
11. Loosen the seven 10mm bolts holding the regulator (three on the electric motor and one in each corner—the front lower one is removed from the access hole from below)
12. Disconnect the power supply from the regulator
13. Fold up the old regulator and remove from the front of the door—place it flat on the floor and take note of the alignment—this will help get the new one lined up right [mine had a broken plastic POS sleeve near the drive motor which was causing the grinding/binding]
14. Fold up the new unit and install thru the front of the door—this might take a while, it is kind of tricky to get right.
15. I had to file the front lower oval mounting hole about 1/16 to fit the new unit
16. Loosely tighten the seven 10mm bolts—align these to the marks you made earlier and tighten all seven (torque to 89 in-lb)
17. There is a plastic zip-tie keeper holding the regulator cables (in an “X) to the inside of the door—push this into the hole from inside the door
18. Take the switch out of the door panel and connect to test the unit—lower and raise a couple of times to make sure all is well
19. Use the switch to lowest setting—make sure to turn off the ignition and remove the switch before installing the window
20. Install the window from the top—I used the OEM window brackets
21. Loosely tighten the 13mm bolts on the window bracket and make an initial alignment.
22. Hook the switch back up and carefully raise the window to the top and check alignment—adjust the bracket bolts to get it right—don’t over-tighten (torque to 89 in-lb)
23. Lower the window and remove the switch
24. Replace the rain shields and rubber plugs
25. Replace and re-connect the speaker
26. Replace the door panel—align each of the six fasteners before pushing in
27. Replace the two Torx-30 screws holding the door panel
28. Connect and replace the switch from the top
29. Replace the two plastic bezels
30. Have a cold one, ‘cause you just saved $600-900!