The window on the driver’s side door on my ’86 Syncro came adrift from the winder mechanism yesterday. I wasn’t really surprised, it had been a bit wonky ever since I got the van. Today I took the door panel off and set about repairing the window. I didn’t take pics of the disassembly, but I took a couple of pics of reassembly to make up.

First, a diagram of the scene:

The regulator comes out with a bit of a struggle, but once out I took it to the bench where it was obvious why the window mechanism had failed. The picture shows the broken part (on the left, parts placed together), plus a couple of spares from my ’82 van. Notice that this piece (as is the winder assembly) is “handed”, ie different for each side.

The replacement part, with plastic guides in place:

Another problem was a missing plastic guide that sits in that rectangular hole in the above part. The plastic bit is fixed to the moving part of the winder mechanism. So I set about getting a guide from my spare assembly:

Maybe that metal part just twists off?:

Oops, I guess not:

But at least I have the plastic guide. Breaking the assembly showed that it is held together by 2 tabs on the “winding screw” projecting through the metal part, trapping the the plastic guide, and the tabs are peened over to secure. So he I go taking the same part off the regulator that I want to repair:

Tabs pressed together:

And the part freed:

Start of reassembly:

On and tabs spread:

The final result:

I guess I should mention that I cleaned the entire assembly and re-lubricated with grease. Now back out the van to re-install. I used a spring clamp to keep the window glass up and out of the way. Here is the assembly clamped on the face of the door to show the orientation:

Wiggling and tilting etc, it goes in:

That vertical track is secured at the top, and at the bottom on bottom edge of door:

The plastic guide tube (which contains the “winding screw” when the window is wound down, is curved and secured by metal tab on door:

Bolting glass carrier to regulator. Don’t tighten bolts up until you wind window up and down a couple of times. Note the hole at top of door that allows access to forward bolt:

There is a little felt pad glued to the outer door skin, I suppose its to eliminate the window rattling at some part of its travel. I glued it back on with double sided tape:

The window winder now works. It was a bit squeaky so I added some more lubrication by squirting some oil down that plastic extension tube. I think the “winding screw” may be worn in parts as the window does not lower smoothly at part, its sort of herky jerky. I’ll look into that some other time.