Things are slow here on the Bronco board lately, so I'll post a couple of topics here and there as I get a chance.

Back about 2001, the driver's side window made the usual sounds and actions of the pegs breaking off of the back of the plastic spur gear in the window motor gear case. I pulled it apart and replaced the broken bits with nylon spacers, and it lasted another 9 years.

In Oct. of 2010, it became intermittent electrically, probably worn-down motor commutator. I replaced it with a new Dorman (2010 vintage) window motor, these had the cast metal gearcase, the gearcase looked just like the original Ford gearcases, at least from the outside.

In Oct. of 2012, two years later to the month, the Dorman motor started having problems. The window when going UP, would stutter, then move OK, then stutter again, etc. It would do the stutter about 3 separate times to get the window up from all the way down. But it wasn't the usual broken-peg stutter. This was louder, and with a different sound, like a metal-on-metal ratcheting sound.

I got on it right away, fearing that the motor mounting had come loose and the output pinion was intermittently slipping on the stamped-steel regulator gear. That thin stamped-steel gear wouldn't take much gear tooth slippage to ruin it, then I would have to replace the whole regulator.

But when I pulled the door apart, the motor was mounted nice and tight. I ran it and looked down there, and when it stuttered, the motor output pinion stopped and started rapidly, but the motor itself kept on running by sound. It appears that internally, that Dorman unit was different. Maybe it had a ratcheting spring clutch in it. I would have loved to take it apart to investigate, but as I had a limited lifetime warranty on it, I took it back to get a new one. The NEW (2012) Dorman motor has a PLASTIC gearcase. With the new motor assembly came 3 thread-forming for plastic mounting screws to be used, as the screws now thread into a plastic case instead of cast metal.

So far, so good. But I am wondering if anyone else had a ratcheting failure of the earlier Dorman window motor with the metal gear case, and if you took it apart to see what was up.

 

My Dorman has been working just fine Torky, do share any info you come by, mine are these btw:
The 5 star featured review in there is mine also .