A chewed-up window regulator roller will mess up your car window. When you raise the windows, the glass might now slide up. Worse, the glass may suddenly drop with a thud. If one or all the rollers are damaged, here’s something you can do to fix it.
Note: This guide is for the 1968 to 1982 Corvette. Check your manual for the window specs and diagram so you’ll know which parts need to be removed to access the regulator rollers.
Difficulty level: Moderate
Things you’ll need:
- Window regulator roller assembly
- Door handle spring removal tool
- Drill with 3/6” drill bit
- 1/4\" drift
- Vise, clamp, punch, and hammer
- White lithium grease
Step 1: Lower the window and remove the door panel. Use a door handle spring removal tool for the door lock knob.
Step 2: Pull out the anti-rattlers on the glass door (found on the door’s front and rear). Then, take out the moulding by removing screws on both ends using a screwdriver, as well as the weatherstrip seal by taking off the screws at either side and the clip in the middle.
Step 3: Detach the glass channel stops through the door’s access holes. Remove the regulator access cover to take out the lower glass channel and regulator.
Step 4: Move up the window until the door’s access holes line up with the screws of the horizontal lower glass channel. Let someone hold the window while you reach up inside the door. Locate the nuts at the back of the lower glass channel and hold them.
Step 5: Make adjustments on the glass run channel outboard on the front and rear to make room for the glass that will be removed. Clear the roller assemblies through the door’s glass opening as the window is pulled up and out.
Step 6: Slip out the lower glass channel from the regulator arm rollers and out the rear glass run channel. When removing the channel, take off the regulator arms by moving the regulator up or down. Be careful with the regulator arms—you don’t want them to close on your fingers.
Step 7: Undo the retaining bolts on the regulator channel. Be sure the position is marked.
Step 8: Pull the regulator arms down. Once the arms are out of the way, remove the regulator through the access hole. For power windows, disconnect any wiring. Take out the regulator by unscrewing its retaining bolts.
Step 9: Use a spanner rocket, needle nose pliers, or retaining ring pliers for removing or installing the glass mounting pads.
Step 10: Remove or install the roller assembly for the front glass run channel using a screwdriver. The shaft will be held by the screwdriver as the retaining nut is tightened.
Step 11: Drill out the peened area on each window regulator roller using a 3/6” drill bit to remove the roller assemblies.
Step 12: Let someone assist you with holding the regulator while you clamp a 1/4” drift into a vise. Then, position the roller’s indented center stud onto the drift shaft. The regulator arm must be fitted over the roller’s shouldered shaft and into the regulator’s arm hole. To expand the roller stud’s hollow end, use a punch and hammer.Then, expand the roller stud on the regulator arm by tapping it with a small ball peen hammer.
Step 13: Remove dirt on the lower glass horizontal channel and regulator channel; apply white lithium grease. Then, disassemble the rear glass run channel roller. Remove it from the lower glass horizontal channel and put in the new window regulator roller assembly.
Step 14: Assemble the regulator and roller channel. Install the regulator and fix the channel on the regulator arm. Then, bolt the regulator in place. Reconnect any wiring and put the regulator and channel back to their original position. During reinstallation, use the marks you’ve made earlier as a guide in aligning the bolts.
Step 15: Reinstall the lower glass horizontal channel. Be sure to align the channel with the regulator arm rollers and slip the rear glass run channel roller into the rear glass run channel. For the alignment of each roller, the regulator arms must be positioned properly. Once everything is in place, have someone help you put back the glass. Place the front glass run channel roller assembly into the glass run channel, after which the glass may be lowered. Reassemble the lower glass horizontal channel onto the glass. As you lower the glass further, have the glass run channel stops replaced. Put the front and rear glass run channel bolts in place, but don’t tighten them yet.
Step 16: Put back the weatherstrip seal, moulding, and anti-rattles. Don’t tighten the anti-rattles just yet.
Step 17: Check if the window rolls up and down easily. If there’s any problem, make the necessary adjustments. If it’s back in good shape, tighten all the bolts. Reinstall the door panel and other components that you removed.