Window Clunking - Solution... NOT!

[System-G]

Heyup peoples.

Yesterday I decided to take proactive action against my clunking and sticking drivers side window. I bought a very expensive replacement cog off ebay (thanks Jinxy) as I was certain this was the root of my evils.

Got the whole lot apart relatively easily (considering access space etc...) and found my original cog looking like this (scuze the quality):


Fitted the replacement good cog from Tony.

Problem solved? No...

My window still sticks 1/3 down and 2/3 down (and also in the same spots on upward travel) and when reaching the top still makes this horrible cracking/clunking sound.
It doesn't look like it's off the runners, but the runners are quite sticky (I know I need to lube them up with some grease (or similar). I am more concerned about the clunking/crack sounds at the top of the run.

Any ideas?

[jasper]

Same thing happened to me a couple of years ago. It turned out to be the cable coming of the spool as it had a slight kink in it. I had to replace the cable in the end.

[System-G]

I suppose I'll need to remove the entire mechanism and check the cable... Any other ideas?

[crazylegs]

sorry to say this but there is another cog in there as well .a big one it sound as if you have a tooth off that as well.problem is it is not an item that can be replaced.my passenger one is like this i have a new mechanism but cant be a--ed to change it all.its a pig of a job.

[Tony jinxy froude]

Hi Garrick, sorry to hear that the cog wasnt the end of your problem, 90% of the time it works but theres alway the odd 10% where it doesnt, the only way to cure sticking channels is to rub a candle up & down the runners, this will sort it in a flash, as Kev says its a pig of a job, what i would do is to buy a secondhand window regulator with everything included & if you have glass cover on your insurance break the window and get Auroglass to replace the regulator at the same time, tell them the window was forced down by whoever broke the window.... food for thought me thinks , Jinxy

[feral4mr2]

i got a new (second hand) cog from a fellow aw11 owner late last year to fix my drivers window clunking problem (last time i made my own cog, it actualy lasted nearly a year.. ).
anyways it worked fine for 2 days and then started to clunk/jam at about the same intervals as yours System-G.

so i just make sure i am hanging onto the window to 'assist' it up.

[Chris \'aka rustboy\' Amm]

i'm sure you can get a whole set of replacement cogs but i forget where i saw them! might have been over at twosrus.com?

[feral4mr2]

yes twos r us do replacement cogs, though they only do the motor driven cog. if the cog that runs the cables floggs out your in for a wee bit more strife.

[Chris \'aka rustboy\' Amm]

yes twos r us do replacement cogs, though they only do the motor driven cog. if the cog that runs the cables floggs out your in for a wee bit more strife.

ah i didn't know that

[System-G]

Thanks for the replies guys

I been away on business for the last week so didn't have chance to reply.

I am also moving so repairing the window properly is off for now. I think I'll get a whole replacement mechanism off ebay or another trusty supplier of MKI bits

Tony, Thanks for the cog. No grudges or nowt - who's to know the full extent of problems until it comes the time to fix... My only "gripe" is that you guys shove things on ebay before advertising them on the forums forcing us to out-bid eachother... all's fair in love and war

[Chris \'aka rustboy\' Amm]

Thanks for the replies guys

I been away on business for the last week so didn't have chance to reply.

I am also moving so repairing the window properly is off for now. I think I'll get a whole replacement mechanism off ebay or another trusty supplier of MKI bits

Tony, Thanks for the cog. No grudges or nowt - who's to know the full extent of problems until it comes the time to fix... My only "gripe" is that you guys shove things on ebay before advertising them on the forums forcing us to out-bid eachother... all's fair in love and war

don't be such a bidding war wimp!

[System-G]

Thanks for the replies guys

I been away on business for the last week so didn't have chance to reply.

I am also moving so repairing the window properly is off for now. I think I'll get a whole replacement mechanism off ebay or another trusty supplier of MKI bits

Tony, Thanks for the cog. No grudges or nowt - who's to know the full extent of problems until it comes the time to fix... My only "gripe" is that you guys shove things on ebay before advertising them on the forums forcing us to out-bid eachother... all's fair in love and war

don't be such a bidding war wimp!

I'm sure my bank manager won't agree with you

[Milothicus]

i went through all the same steps as you this summer, except i stripped 2 screws. wasn't easy getting a dremel in there to grind off the screw heads....

i shoved my digital camera between the doorskins and started shooting. what i think i saw, was that the next gear from the motor is actually the spool that winds up the wire, and that's where you're missing a tooth or two. as has been mentioned, you might as well change the whole mechanism. the BGB has detailed instructions on how to disassemble the door completely. i posted them in the wanted section a while ago if you search for it...

my car's missing one, so it sticks halfway, and if that gear happens to be in the wrong position at the top, it makes that terrible banging/ratcheting noise.

[System-G]

Cheers guys,

Managed to get a complete mechanism off a local bloke for a good price (less than what my replacement cog cost on it's own )

Removing/replacing the mechanism should be OK as I've had to do it on previous cars. I have the BGB and Haynes at hand if need be...