Door panel Bulge
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New User
Joined: Apr 2018
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Door panel Bulge
Hi new member here. I have found a lot of great advice and knowledge this far which lead me to becoming a member. I have a 1993 f250 xlt and when I roll my driver side window all the way up the door bulges out quite a bit. It did this with the previous window regulator and in trying to figure out the problem I burnt it out. I bought a dorman replacement 741-674 and it seems to be worse. Anybody ever come across this? Or find a fix? Passenger side does it as well and I havnt touched that side. My driver side is all taken apart all new parts to put it back togethar and I want to do it right the first time. Thanks
Elder User
Joined: Jul 2011
Posts: 793
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From: Vernon, BC
My 1994 with electric windows did this too. I simply didn't wind the window up as tight as it would go. However, it is not supposed to do that. There is supposed to be some kind of stop designed into the system to prevent the window from being raised too high. When it does happen the mechanism twists and puts pressure on the door panel causing the bulge. I never looked into it but I think there is supposed to be a tab on the window mechanism to prevent it from going up too high. I don't know if it is located on the window crank gear or on the mechanism attached to the window slide. Look for bright shiny spots on metal that look like they should stick out and get in the way???
Sorry, not sure how to word this. I hope this gives you something to look for that will allow you to track down the issue.
Sorry, not sure how to word this. I hope this gives you something to look for that will allow you to track down the issue.
Senior User
Joined: Jun 2017
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Not sure what you mean by quite a bit or door bulge. It is normal for the inner door panel to move when the window stops moving and the motor stalls. Electric motors produce maximum power at zero RPM.
There is no tab to stop the window at the top of travel. It just nests in the top of the rail.
Unless the regulators mounting points are cracked or broken, there is nothing to worry about.
There is no tab to stop the window at the top of travel. It just nests in the top of the rail.
Unless the regulators mounting points are cracked or broken, there is nothing to worry about.
Thread Starter
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New User
Joined: Apr 2018
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So when the window reaches the top and nests inside the channel a little bulge out or flex from the door panel is ok? I've talked to a few other guys locally who own different makes and models and the general concescus is that "it's just that way." So I moved on. Next thing. That new dorman regulator is wired backwards. Now on my power window switch up is down and down is up.
Elder User
Joined: Jul 2011
Posts: 793
Likes: 2
From: Vernon, BC
Everyone may be right about the bulge in the door panel when the window goes all the way up. However, my 92 doesn't do it. Maybe it's the "different" one. 
At any rate, I had the truck from 2011 to 2017 and it was not a concern of mine so you should be OK.
At any rate, I had the truck from 2011 to 2017 and it was not a concern of mine so you should be OK.
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From: Gilbert, PA
Not sure what you mean by quite a bit or door bulge. It is normal for the inner door panel to move when the window stops moving and the motor stalls. Electric motors produce maximum power at zero RPM.
There is no tab to stop the window at the top of travel. It just nests in the top of the rail.
Unless the regulators mounting points are cracked or broken, there is nothing to worry about.
There is no tab to stop the window at the top of travel. It just nests in the top of the rail.
Unless the regulators mounting points are cracked or broken, there is nothing to worry about.
Agreed 100%
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