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My driver side is doing the same. I went to buy the "gear kit" and they are $29.99 locally. Went on Ebay and found a brand new motor (not rebuilt) for $28.00 shipped.
So when I get paid tomorrow im going to order the whole new motor.
I ended up buying a new Dorman motor after the NAPA rebuilt one I installed didn't work.
I'd rather put a new motor in that keep hassling with rebuilts that don't last as long.
I finally got this fixed, we carried a new gear at work for $18. When I took the old gear out, I noticed it wasn't actually a gear that was ruined. There is a large plastic gear on one side and a small metal gear on the other side. They are connected by three plastic ***** or blocks. I'm not sure what they were since I had nothing left but plastic bits. Strangely enough, my new gear and old gear were completely different diameters and the new metal gear was twice as thick as the old one. I was able to separate the new assembly which had solid rubber blocks and use them to connect my old gears. Everything works as it should now.
The gear plugs I got from the new gear were solid rubber, just flexible enough for me to squeeze the metal gear into the plastic one. I dont see them failing the same way the plastic ones did.
Did the nut trick make your window clunk when all the way up or down? Only reason I didn't do that is I heard it makes your window motor alot noisier.
Nope, as long as they are the same size as those rollers, no clunking. Now in my car, the 3/8's nuts were little smaller than those rollers, so it does clunk!
I just found those gear plugs at my work, same part number too. I'm thinking I will buy them, put them in the gear I already bought and return it to get my $20 back. That way I am only out the $7 for the plugs.
You can also go to Ford and get a rebuild kit for the motor. I've had to do this twice to my Bronco, once for the driver's side, once for the rear window.
This is what Ford sells, it's not a rebuild kit per se, as it only replaces the plastic drive gear that is notorious for stripping.
Note: This kit is also available from parts stores, but...there are TWO different kits.
You want the kit that fits 1970 and later, not the kit that fits 1965/69.
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The plastic window roller has nothing to do with the window motor. It's present whether you have power windows...or not.
The roller attaches to a stud on the window regulator's arm, then fits into the channel that's attached to the door glass.
What usually happens: The roller breaks, the window jams up in the channel, or falls down into the door.
D6AZ5323240A .. Window Roller / Use with or without power windows.
Fits: 1980/91 F100/350, Bronco, Econoline / 1976 and later passenger cars.
MSRP: $7.88 // Y2KFORDPARTS.COM price: $5.68.
1992 and later F150/350, Bronco, Econoline: The roller is not available by itself, it only comes with the window regulator.