Rebuilding a Power Window Regulator (Gen3 Maxima)

This assembly is not made to be serviceable but a cable jam isn't enough reason for me to buy a new one. So here's how I did it :)

First, inspect some irreparable stuff. Regulators are made with plastic pulleys, holders, etc... So they are really vulnerable to damages. As you can see, the regulator is jammed in the pulley section.

Step 1: Analysis

Analyze how was the jam.

Step 2: Dissasembly

You cannot reroute the cable without removing is cap. The cap is attached to the body with three hollow rivets. Using a drill will permanently remove these rivets.

Drill those sections and pull the cover out. Set the cover, pulley, and the rubber thing aside.

Step 3: Rerouting Cable

Reroute cable, place the rubber spacer, put some grease, and attach the motor. It will require great imagination to find out what direction the crossing cables should be.

NOTE: Rerouting the cables will require a lot of patience since they're pulling each other, the tension will make it hard to align the pulley in the center and it may also come apart. You may also want to consider the correct placement of the cable housings on the upper and lower white half pulleys. A silver pellet-shaped metal in the middle of the cable is the one responsible for the coordination of the window to the regulator. Be sure that its white plastic socket isn't broken.

If you're able to join them successfully, the pulley will be aligned in the center while the motor is holding it. Then, temporarily secure the motor and the base with 3 screws.

Step 4: Cap Installment

To reattach the cap, we're using a welding epoxy while aligning the three holes we drilled earlier. The tension of the cable transferred to the pulley may misalign the cap while curing the epoxy. That's why we attach the motor first to keep it in place.

The epoxy will have to cure for 24 hours without any movement. But epoxy alone can still be weak. It is recommended to use three 3/16" or 1/4" diameter rivets to replace the drilled fasteners earlier. To do this, you have to remove the motor first and attach the rivets from the underside. Reattach the motor.

The power window assembly is now ready to be installed :)