Recently the driver-side power window on my daily driver – a 2000 Ford Ranger with 175,000 miles, started making clunking and chattering sounds when it reached the fully UP position.
I suspected the window regulator, which controls the window movement and is driven by a small motor. A replacement was ordered from my local auto parts store and I had it within 24 hours, for a cost of $50.00. I was bit surprised how easy it was to get to, remove and replace, the entire process from start to finish took about 2 1/2 hours or so, and I’d never done this before.
The biggest challenge was drilling out the four rivets that held the regulator/motor assembly to the inside of the door. I used stainless steel 6mmm bolts/washers/nuts to replace the original 1/4″ rivets during reassembly, one of which was behind the regulator arm. I used tape to locate the bolts in place and inserted them through from the inside so the bolt threads were on the outside of the door. I cut them to length with a Dremel when everything was snugged down as the bolts were a little long and I didn’t want them to interfere with the door panel.
The issue with the regulator was several teeth on the control arm that engages the drive gear on the motor were damaged. The photo shows the defective teeth, pointed to by the pencil.