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I just replaced my drivers side motor a month ago, the plastic gear was broken. I got one from the junk yard. Now that one is broken too. I'm trying to decide if I should go new or back to the junk yard.
Been there, done that. An old motor will just fail like the last one. you will get tired of pulling them out. The plastic pegs are the weak link. Rebuild your motor for good, 3 options:
1 Buy a rebuild kit at a parts place.
2 clean out grease and broken bits use 3 nylon spacers from Home Depot to fit in the space and regrease with black wheel bearing grease.
3 clean real good and JB Weld the metal triangle to the back of the plastic gear, fill the back pockets around the triangle and let dry for a day, then regrease. If doing the last, don't get JB where it ain't supposed to go, like on gear teeth or shafts!
A new gear set is about 25.00 at the AZ. Make sure you completely clean out the housing. I was in a hurry and almost did'nt do it, but when I washed the old grease out of the housing I heard the clunk of hard fragments in the pan. That new gear would'nt of lasted long.
My problem is the driver's side window just goes dead. A mechanic told me to whack the motor with a hammer, which I did, and I pushed the button and it worked fine - for a while. Been whacking that motor every week or so for a year now,(got a wooden hammer handle, works just as well) but getting tired of driving around with the door panel in the back seat. Will a rebuild kit fix my problem too? Actually works real good after I whack it, doesn't sound like anything is broken inside. In fact, I have had the motor out and apart and put it back in, didn't have to drill out anything to do it like someone else said elsewhere in this forum.
I replaced the motor and the gear in my '86 F250. The whole assembly was about $50 at O'Riely Auto Parts. Since my A/C is not working, the window has had some pretty good use, and has been working for about a year now. No complaints except that I did have to drill out the old rivets and replace with bolts. I did buy the replacement gear assembly (also) at AZ, and forgot to return it. If you go the route of just replacing that, I'm sure I could make you a deal.
The replacement motor gearbox assemblys are only about $50. from Pep Boys etc. The "hit it with the hammer" thing is probably the whole sliding assembly wedging itself at the bottom of the stroke. Mine does that, don't let the window slam all the way down under power. Another thing that happens to mine is if I let it sit in the sun and the door gets real hot the cutout switch in the motor won't let the window do anything until it cools down.
Weeellll, I went down to the local auto parts store and asked and VIOLA!, they had a driver's side motor (rebuilt) in stock, $60 after taxes and turn in the core, and it's in and it's "woikin" and I'm now looking for the door panel and stuff (seriously disorganized guy here)
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