Sorry to revive an old thread. The OP has probably done the job already, but anyway, my 2 cents. This is for the novices at this sort of repair. Seasoned mechanics may not get much out of it (but you can fact-check me if you like):
I recently repaired my driver's side door motor. The urethane bushings were ground into a million bits (yes, I counted them! ok, I didn't).
Don't plan on replacing your original '96 metal gear assembly that press fits in/atop the bushings with the one from Cardone, because it DOESN'T FIT W/O MODDING. The lip/rim of the sleeve sits too high to fit under the gear housing seal plate. I was determined to make it work, so I spent more time on it than I should have. Filing that sleeve down took a long time -- had to go easy and do many fit checks or I'd have filed off too much; and it filed like it was hardened steel (the sleeve), using an almost new file. If your old gear assembly isn't trashed, save yourself the trouble and reuse it!
All you're likely to need for most stuttering/bumping/stalling fixes are the new urethane bushings anyway.
The Cardone plastic worm gear appeared tough enough and it fit the motor housing just fine, so I used it.
Those considering repairing their own window motor need to be mindful of the regulator counterbalance spring. If you remove just the motor from the door w/o the regulator arms fixed in position, the spring will snap the regulator arm down HARD toward the bottom of the door after you push out the last motor bolt -- if your finger(s) are caught in the wrong spot, it is forceful enough to do serious damage to it/them.
IMHO, it's better to remove the regulator with motor attached, for several reasons:
1. It's safer, because the motor gear will keep the spring in place -- use a bench vise to help you ease off the spring tension as you dismount the motor.
2. You can clean the regulator with it off the vehicle -- mine was getting some rust, so I wire brushed it down nice-n-clean. I also removed all the old lube with a screwdriver and aerosol cleaner, as it was dry/hard in spots.
3. You can easily relube the regulator -- can be done on vehicle, but much more difficult to get at and you can't effectively clean the old lube gunk off (trying to will make a mess inside your door as well). The Cardone kit came with some kind of red grease (it looks like bearing grease), which I used on the metal external gear, but I opted for white lithium grease on the internal worm gear(s), regulator joints, spring and plastic channel slides. I already had the lithium grease in a syringe, ready to get in the recesses; the red grease packet had a cut-away "nozzle" end that made for easy enough application on the motor gear.
If you're worried about drilling out the large rivets, don't. You do not need new rivets. To reattach my regulator, I used stainless, truss head (perhaps they're panhead, but a low-profile version if so) hex bolts with stainless, external-toothed lockwashers and stainless nuts. I got these from the local Home Depot and Lowes, so they aren't hard to find.
The bolt head goes on the inside of the door to ensure clearance and there's room for the nuts/washers in the rivet pits on the trim side of the door. I used a 3/8" drive hex bit to tighten them down -- people with really large arms/hands might have difficulty with this, as it's a tight squeeze in there and you have to feel your way around to get the bit engaged on the bolt (there's no room for even a small lighted service mirror; I tried it). A 1/4" drive with a shorter bit might help some, but there's still very little maneuvering room in there.
Sorry, I don't have the exact bolt dimensions handy, as I've misplaced the packaging and the bolts are on the assembled door. I can look for them if anyone needs specs.
Meanwhile, just measure the holes in the door, the thicknesses of the regulator, door and the nut+washer, and get bolts just long enough that the ends are flush with the nut once tightened. You can cut them to length, but stainless IS tougher to machine, so best to get the right length to begin with. You don't have to use stainless, of course. I chose to because I didn't want to take the chance of having to deal with rusted bolts should I need to remove the regulator again. Stainless hardware does cost more, but it was worth it to me. I know, zinc plate... but I couldn't find any the right size and they're not as rustproof as stainless anyway.
The motor itself was a mess. First, I had to clean out all the bits and pieces of bushings. They were in every conceivable nook and cranny of the entire housing. To remove it all, I had to completely disassemble the motor. For the uninitiated, reassembly can be tricky if you aren't careful. You should note the order and orientation of the parts as they're removed so you don't forget something, and you must remember to use the brush retainer to keep them off the rotor during assembly -- otherwise you'll be tempted to push the rotor back in normally, but it won't fully insert (even though it looks like it should fit!). This is not my first electric motor disassembly, not by a long shot. However, everything flew apart upon dismantling this one, so it took me a while to figure out how the brushes were held in place -- it's done with a plastic shaft sleeve (one which I had carelessly placed away from my work area). When you push the motor assembly back into the gear housing, the worm shaft catches on a rim, which in turn pushes the sleeve down the shaft and off the brushes, freeing them. Whatever you do, do not lose or damage this retaining sleeve! Because the brushes are completely covered by the motor casing during reattachment to the gear housing, it is impossible to get any tools in there to manually hold the brushes, and you'll be hard pressed to find a suitable replacement, even from a plastic supply house (e.g., a tube to cut one from).
My motor has been working flawlessly for months with the Cardone kit, after the aforementioned mod, which shouldn't have been necessary. The window is faster/smoother than the passenger side, so I may refurb that one soon for good measure, even though it's been used far less than the driver's side.
Last edited by Torque; 07-16-2010 at 03:14 PM.