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  #1  
Old March 3rd, 2012, 02:51 PM
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Station Wagon Windows

Aside from the problems of doors rusting inside and out, another problem that the station wagon doors have is the windows.

This manifests itself as the windows not rolling up properly for any reason, or not winding up properly for any reason. The windows could fall in the door, one side rolls down faster than the other etc.

To understand why these issues occur, it's important to note first that the window channels (the felt-lined channels surrounding the window) have absolutely nothing to do with whether the windows wind up or down properly.

In fact, an SW door without window channels should operate perfectly, except to let in a lot of weather (rain and wind.)

Given this fact, then, there are several parts of the window winding mechanism that can fail:

1. Upper internal door roller track.
2. Lower window-mounted roller tracks.
3. Window regulator gears.
4. Window regulator "free arm"

Function:

The window regulator works like a pantograph mirror. There are two arms, a "geared arm" and a "free arm". The bottom ends of the geared arm and the free arm terminate in rollers which mount in the lower window-mounted tracks. These rollers are designed to remain perfectly level as the window regulator gears are turned. This, in turn, causes the window to remain perfectly level as it is wound up and down in the door.

The top end of the geared arm terminates in the window regulator gears.
The top end of the "free arm" terminates in a roller which mounts in the upper internal door roller track.

Problems:
Failure of the window to wind up or down in parallel

The first thing to check is that the door-mounted roller track and the lower window-mounted roller tracks are in good condition and properly aligned.

The next thing to check is that the "free arm" remains straight during operation. If the roller tracks are in good condition and properly aligned, then it is most likely that the "free arm" has broken in half.

The construction of the "free arm" is actually in two pieces. The two pieces of the free arm are connected to the center of the "geared arm" at the factory, then spot-welded 180 degrees from each other after a pivot is put into place. Therefore, if the spot-welds break on the "free arm", then the free arm is free to swing in two pieces, causing the uneven opening of the window.

This is a poor engineering design. You cannot fix this problem by simply tightening the pivot bolt. This will only make it difficult to wind up and down the window.

The only correct fixes for this problem are to buy a new window regulator, re-weld the two pieces of the "free arm" together, or to drill a hole through the "free arm" halves in the correct orientation and use a screw to hold the arms together.
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  #2  
Old March 3rd, 2012, 05:30 PM
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Nice write-up, Thanks !!
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  #3  
Old March 3rd, 2012, 07:14 PM
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So what's wrong with yours?
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Old March 3rd, 2012, 07:16 PM
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Mine were falling "forward" during winding down and up
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Old March 3rd, 2012, 07:19 PM
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Right, but what's wrong with it? Did the spot weld break on the free arm? You list 3 fixes - did you do one of them? How about a picture of the real deal?
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  #6  
Old March 3rd, 2012, 07:43 PM
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In mine, the spot welds were broken! As far as pics go, hold your horses They are coming...
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  #7  
Old March 3rd, 2012, 08:04 PM
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Quote:
Originally Posted by sonoronos
In mine, the spot welds were broken! As far as pics go, hold your horses They are coming...
If you need a hand welding it, let me know.
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  #8  
Old March 3rd, 2012, 08:07 PM
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Thanks, btw I am in for the barn raising!

I am a big fan of phosphoric acid dip. The completely rusted bottom window rails after soaking in prep and etch for 4 hours.
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  #9  
Old March 5th, 2012, 08:41 PM
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The TIG is useful for this job. Drill the center hole out and clamp with a pointed welding clamp. Using 100 amps DC, achieve complete fusion via autogenous weld. Once fusion is achieved, fill with ER70S6 or whatever you like.
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  #10  
Old March 5th, 2012, 09:46 PM
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Replace all parts, install new window tracks/felt like I did, and regrease the tracks with synthetic grease, and you are done. Your window will now move up and down perfectly level.
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  #11  
Old March 6th, 2012, 07:48 AM
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TIG! Showoff!

Good to see you got it sorted out.
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  #12  
Old March 6th, 2012, 08:26 AM
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I would like to see the pics of you using the TIG on that carpet!
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  #13  
Old March 6th, 2012, 09:11 AM
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Tig + carpet = fire

All work done on my patio/workshop/rover parts facility
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  #14  
Old March 6th, 2012, 09:35 AM
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Ed, Hydrochloric acid works just as well and you can get it at the hardware store. Only thing is you gotta be careful with it cz it gasses like fury. Outdoors is best.
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  #15  
Old March 6th, 2012, 09:47 AM
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Thanks Bill...I'm scared of HCL...the phosphoric seems less dangerous to me especially at higher concentrations

I also get the iron phosphate layer
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