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I'm on my second window regulator assembly and the cable has fallen off track. I would hate to have to buy a new one if all I need is to get the cable back on track. Is there any way I can get the cable on the pulleys without having to buy a new window regulator assembly? The cable is so taught that I cannot get it on the pulleys.
Are you trying to put the cable back on the pulley with the glass still in the door?
You may have to get all the weight off the cables to get them back on track. However, they are spring loaded at the gearbox, so you should be able to get the cables back on track without taking everything apart.
Worst case would be you have to take the window regulator assembly out of the door, open the gearbox, and remove the cable from the drive assembly to get it back around all the other pulleys. Then put the drive spool back in the gearbox.
One way or another, you should be able to get the cable back on. My question would be what makes the cable keep coming off anyway? You need to fix that problem before putting everything back together.