Replacing tailgate window channel/regulator

[Matthew W. Woodruff]

Installed two new tailgate window side channels this weekend (thanks BJ's) and in the process I dislodged one of the washers/keepers that hold the regulator lift arms to the tailgate window channel.

Do I have to remove the entire regulator unit to snap the washer back on?

Looks like the washer rides in the slots on the window channel and should just snap over the end of the regulator arm. Are there any tricks involved in fixing this?

[Bob Barry]

No, just poke the pin through that slot on the lower window channel, then be patient while you're trying to snap all four fingers of that washer back over that pin and seat them in that groove.

[BK]

That washer has a bunch of little fingers on it that sit in a groove when it's snapped on. If you are not real careful taking it off finger by finger it gets ruined. I broke one on one side and used a bolt and large washer in place of it to hold the arm on the lifter. Space is really tight near the end of that arm though. You either have to put your arm in there and do it by feel or like I did which is to cut a slice and peel back the metal to gain better access to the inside. When the panels are back on you can't see where the slice is made. Also helps to do this with the window down and tailgate open.

[andy d]

i made 2 acess holes with a 2" holesaw. my hands are too f'ing big to get in there

[Matthew W. Woodruff]

Thanks. So here's a followup:

Will removing the regulator *allow* me to fix the washer (without cutting holes in the tailgate)?

I managed to loosen 4 of the 5 screws holding the regulator, but the last one was too tight even with a liberal dose of PB blaster. I will try it again this weekend.

Assuming that I can get all 5 screws, the regulator should just drop down far enough for me to fix the washers, right?

If I leave the motor connected, I shouldn't have to worry about the gears cutting off my fingers, right?

Thanks.

[turtlejoe]

My TSM says to place a 1/4 by 1 inch long screw with washer between the gear teeth, starting from the bottom up. You want to get it wedged in there well enough to keep the gears from moving once you drop the regulator. The head and washer should be between the gears and the outer skin of the door.

I've been monkeying around with my window for a week, and after tonight it looks like getting to the washers without extra holes is doable. Applying enough force to seat them in the groove though, may be a different story. I took the opportunity to grease the slots in the channel though, 'cause they were bone dry.

Good luck!