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now ive got the million dollar question "does this black part" have a part number? I think this might be why my window has so much play in it.. I have a real good idea the body shop lost it when they worked on my door but I couldnt get them to fix the window.. So ive done it myself...
never mind guys. I somehow found that little piece after the window being broken for over a year.. It was hidden in the corner of the door. Thanks a million TheRadioFlyer for posting those pics. I would of never tried to do this without them. I just hope i can figure out why the window wont roll down with out the door open.
Finally tore into the Driver's door panel to check this out and everything mentioned so far looked tight, but I think I found at least part of the source of the problem. The photos below show slack in the regulator cable that appears when the window is in the full up position. I also notice (now that I can see inside the door) that when I push the down switch the motor runs for a second before the cable starts moving on the pulleys - so I am guessing that it is having to coil up the slack shown below before it can move the assembly. It also feels like maybe the plastic retainer next to the spring that attaches to the forward/lower cable aperture on the motor is loose. I guess this means new regulator - right?
The tube that the cable runs through is spring loaded on each side of the motor. Can you tell if the spring is loose on the side with the slack?
It may be that the drive gear has slipped (or stripped some teeth) and the cable is uneven on each side of the motor. You could take the drive gear assembly apart and try to rewind the cable, but it still may not last very long.
Replacing the whole regulator assembly is easy, but the dealer cost is about $400. You can find them cheaper on the internet, but make sure you get original equipment.
If you replace the whole assembly, it really helps to put masking tape on the window and the outside door trim and mark the position of the glass in the up position. Makes it a lot easier to get the glass back in the exact same position.