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Last Sunday the window made some very bad noises as if pieces of small glass where screeching the inside of the car door and the window would no longer operate. What had actually Happened was the cable that is used to move the window up and down had become frayde and broken. Here is the new cable at around £20. Before you consider doing this yourself read through. To fit the new cable I did need a second pair of hands - so arrange someone to be with you for that part. So lets go through how I repaired my mechanism on my Skoda Superb.
Open the car doors and then before starting to do any work remove the negative lead from the battery. Door card requires removing. This is done by first removing the cover over the pull handle.
The cover 'simply' pulls off. Although I found it to be very tight on and had to use a screw driver behind it. If you know where the moulded clips are then it makes it easier to know where to prise off.
Here can be seen a clip
And another at the top.
Once off you'll wonder what all the fuss was about getting it off.
The spring clips help keep it in place.
Anyway once off you can remove the two screws located in the door handle, using a phillips ended screw driver.
And the bottom one.
There are 2 torx screws along the bottom of the door card. These need removing.
One is by the light
And there is one on the opposite end.
I used a Torx T25
Which fitted perfectly.
The second out.
Door card is still fixed by clips to the door.
Put a flat bladed screw driver behind the door card
And gently lever. The clips will give and the card at that end will come away from the door.
Same again the speaker end.
And lever the bottom away slightly.
As you can see the door card comes away slightly but is still held in place. DO NOT try removing it yet
Look at the bottom of the door card.
What is stopping it is the wiring to the lower light.
This wire here.
Unclip the light fitting, pull it thought the hole and take the wire off. Put the light somewhere safe. Push the wire back through the hole.
The door card can now be moved outwards along the bottom edge so you can see up it and what is behind it. Here we can see the motor and more wiring.
Gently pull the door card upwards and outwards. The clips will release and the door card will come detached from the door.
DO NOT REMOVE THE DOOR CARD YET. KEEP IT HELD.
The doorcard comes away but is still attached to some wires for the window switch and the door pull cable. Angle the door card to pass over the lock pull lever.
Here we can see the pull cable in the background and the electric cables in the fore ground.
Remove the door cable hook and clip.
It comes away easily.
Unplug electric cables from the switches.
The door card should now come away
With the door card out of the way we have internal door plate to deal with which the window mechanism is attached to. The motor is on this side and the cable and runners are on the opposite site.
We need to deal with the cabling.
Remove the speaker cable
Unplug the electrical connectors at the top.
All slightly different with different clip arrangements.
But simple enough to undoe.
All removed from here.
Now remove the cable connector from the electric motor. pull the clip down which will release the electrical connector.
On the plate there are two large black rubber covers
Open there gently with a flat blade screw driver.
This always us access behind the plate which will be required late.
So here is the plate. We are now going to remove the gold coloured screws around the plate apart from the top left and top right ones (which will keep the plate in position for now).
Go around removing the gold screws around the plate.
Remove the ones at the top (apart form the ones at the top corners).
Now push the window down slight until you can see the window carrier bolts through the two holes we opened earlier.
Push the wind down until you see the bolt as the above picture.
And the same for the other hole.
Use some strong tape on the window glass to hold it up.
IT MUST BE STRONG TAPE OR THE GLASS WILL FALL AND SMASH.
I used duct tape.
Loosen the bolt slightly so that it no longer grips the glass
- BUT DO NOT REMOVE IT.
Move to the other side
Do the same on this side.
Do not move anything yet.
Right time to remove the two far screws
Remove screw one
Remove screw 2
The door pull cable needs to be pushed through the door card.
Push the gromet through the door card.
And push the cable through.
Make sure the cable is out of the way on the other side.
Now to remove some cables. Push the gromet through with your fingers. Note the metal edge will be sharp.
All the way. You will also notice the 3 black connectors ( to the left of the hole my finger is in). The first bottom one which is removed pushes out from behind and hence is removed. The top two do not. We will come back to these in a moment.
Pull the top of the door plate away and using long nose pillers undo the cable clip on the right hand side and
pull away the cables
On the door lock side of the door plate, prise it open so that you can see the other side of the 3 black pins. To remove the only way I could find to do it was to put a flat blade driver behind the black plastic bracket and gently pry it apart. Be gentle as you need to put these back in place after. Do this for the first lug and
repeat for the second.
Away it comes undamaged.
Back plate with bracket removed leaving the three holes.
Put some tape over the door lock pull to protect it and move back plate to put lock pull through.
Back plate is now free apart from cabling that is attached.
using long nose pillers behind the door card squeeze the cable clips and up them out.
Repeat this for all the cable clips.
The only cable still attached is the one that goes through the hole on the left to the locking mechanisms.
The door plate can be lower now for access to this last cable.
It is attached to the lock here.
It simply unplugs when
you put a screw driver blade on the release clip as shown here. Once released remove the cable from the back plate.
The back plate is now removed. You can see the runners back of the motor and cable. This one is corroded and broken.
Remove the old cable.
Remove the 3 screws off the motor.
two and three and remove the cover.
Inside you will find the cable ends and the gear wheel, (On mind it is a tangled mess).
Take the gear wheel out and remove the cables. They simply come out.
There is a lack of pictures for the next bit but it is simple to do if you have patience and a second set of hands. Hence why I didn't have yet another for a camera!
In the new kit you will have a new cable, two new plastic clips for the runners and a new gear wheel- you will need to use all the new parts.
Check new cable against old one.
Remove all the old cable.
Remove the old runner clips (which will be attached to the old cable with some barrell nipples on the cable.
To remove the plastic runner clips first prise off the metal part that clamps the window glass. (This allows you to rotate the clip)
Rotate the plastic clip through 90 degrees and release it from the runner.
Fit new plastic clip in the same manner.
Fit window clamp to plastic clip.
Repeat for the other side.
Now layout the cable along the route. Do not put around wheels yet
Put the barrell.nipples in the plastic runner clips.
Put the cable around the the bottom left guide
(The bottom guide is a tight fit for the cable I bent the metal back with pillars slightly)
install cable around the top right wheel.
This bit is where the second hands are required.
Put the cable ends in the new gear, while winding the cable round as much as possible and place in cover.
Fit the green sprung ends to the cover.
Refitt the cover of the motor while not letting go ;)
Next finish routing the cable around the other two wheel. The cable will be a very tight fit and on the last two wheels do not put the cable around the wheels but as the next picture
On the camed section
Do this for the other wheel
Using some piller, insert the nose in the plastic wheel and rotate the cam round.
The cable wil locate around the wheel as it goes round
Repeat for the other wheel
and in place it goes.
Give all a check over to make sure you are happy with everything.
I re-straightened the metal around this guide to make sure the cable would not come out again.
Time to put the door plate back on.
Position the plate, put the cable to the lock through and plug into the locking mechanism.
Put the door lock pull through and position the grommet.
Put the door handle cable though the back plate.
Ensure the cable is routed correctly so that it will not interfere with the window going up and down.
To put the back plate in you have to have the back plat too high as the window runners are lower than the door card. So lift into the door and then lower it into position.
Connect some of the wring to the back plate including the motor plug.
Position and then check through holes
In my case the window glass clamps were not in position to connect to the glass.
Same on the other side.
Push the bracket through with the 3 black prongs.
It should clip into place and not drop out.
With most things back in position the back plate can be bolted back on.
Install the gold screws around the parameter of the back plate.
and along the top here
and here under the speaker
and last one here
then tighten them with a spanner.
Well these need moving up to continue.
So with wiring done apart from the switches on the door card.
The door card is moved adjacent and the plugs connected to the door card switches. The battery is reconnected to the car.
The iginition is turned on and window switch used to raise the clamps. A good sign if they do move :)
Move them up until the screws can be seen.
On both sides.
Hold the window glass and remove the tape.
Lower the window until it rests on the clamps. Then push down so that the glass enters the clamps.
Ensure the glass is full yin the clamp.
And on the other one too.
and tighten the clamp screw.
And the same on the other side.
Put the black covers back over the holes and tidy any wiring up.
Now test the window.
All the way up and
All the way down.
Push lock down to make getting the door card on easier.
Remove speaker surround.
Position door card and be ready to connect door hand pull cable.
It hooks and and clips into this sleeve.
Put the door card into position and then lower it. Push all around to get the clips to install.
Feed the wires through to fit the lamp at the bottom of the door and insert lamp.
Install the two torx screws under the door card
Installed the door handle grab screws
Handle screw 1
handle screw 2
Ensure they are tight.
And refit cover, mine needed to be banged hard into position
Door card done
And a working window again. All done.