Power Window - Motor & Regulator Assembly Procedures
NO. TSB-97-42A-003DATE: February, 1997
MODEL: See Below
PURPOSE
In the past, the power window motor and regulator were supplied as a complete unit for replacement parts. For listed models the motor and regulator are now available separately. The affected service manuals do not include instructions for motor and regulator assembly or drum and regulator wire assembly. Use the instructions in this bulletin along with those in the service manual when replacing the power window motor and/or regulator.
AFFECTED VEHICLES
1992-97 Montero
1992-95 Expo/Expo LRV
AFFECTED MANUALS
The following manuals do not include the procedures covered in this bulletin for power window motor/regulator assembly and drum and regulator wire assembly.
1992-95 Montero Service Manual Volume 1
1996 Montero Service Manual Volume 1
1997 Montero Service Manual Volume 1
1992-96 Expo/Expo LRV Service Manual Volume 1
PROCEDURE
^ POWER WINDOW MOTOR AND REGULATOR ASSEMBLY
CAUTION
Be careful when handling the power window motor. otherwise, the wire may come off the drum due to the reaction force of the spring.
1. The new part comes with a tie-wrap to hold the assembly together during shipping. This tie must be removed before proceeding. While holding the case and metallic cover by hand, cut off the tie-wrap with side cutters or similar tool.
2. Remove the metallic cover.
Note:
If the wire has come off of the drum, restore the wire according to the DRUM AND REGULATOR WIRE ASSEMBLY procedures elsewhere in this bulletin.
3. Using the guide and motor housing opening and drum housing guide tab as assembly reference points, align the drive shaft of the power window motor to the square hole in the drum.
Note:
^ For regulator motor and regulator phase alignment, slide the glass bracket (glass mount) to a distance of 12.7mm or rotate the drum with a ratchet wrench handle to achieve the same movement of the bracket.
^ Rotation of the drum may cause the wire to come off the drum. To prevent this, hold the drum and guide with your hands.
4. Align the guide and the motor housing opening. While holding the guide and the drum, let it slide into the motor housing.
Note:
To prevent drum runout, bend the lugs so the metallic cover is not loose. If the drum has runout, the glass may not lower or lift smoothly (example: may rattle when lowering).
5. Align the metallic cover lug with the metallic cover mounting hole. Be sure to bend the lugs to secure the cover to the housing.
Note:
When replacing the regulator assembly (service part), use a new metallic cover that is in the set. When replacing only the motor, reuse the removed metallic cover.
6. Apply battery voltage to the power window motor to make sure the glass bracket moves smoothly.
DRUM AND REGULATOR WIRE ASSEMBLY
1. Place the drum, guide, regulator, etc. on the work bench as shown.
a. Place the drum so the square hole side faces upward.
b. Place the guide with the slits up.
c. Place the regulator with the glass bracket down, and leave the glass in its fully open position.
Note:
Use only one spring (A or B) depending on the model being repaired.
2. Put the wires through the springs. Install the lowering wire to the guide first, then install the lifting wire. (The lifting wire should be placed over the lowering wire.)
3. Using a wire (about 0.5 mm in diameter) and twisting, compress the spring.
Note:
Bind the wires at a slit portion of the guide.
4. Insert the leaded end of the lowering wire into the wire hole on the bottom surface of the drum. Make sure that the wire is wound on the first groove of the drum without any looseness from the underside of the drum.
5. Wind the lifting wire onto the drum.
a. Insert the top end of the lifting wire in the wire hole on the top surface of the drum.
b. Raise the forward part of the drum to its upright position and put the lifting wire into the last groove in the drum.
c. Place the drum in its original position making sure to hold the drum so the wire does not come off.
Note:
For assembling the power window motor and regulator after the drum and wire assembly is complete, refer to the POWER WINDOW MOTOR AND REGULATOR ASSEMBLY section at the beginning of this bulletin.
6. Cut off the wires that have been used to compress the spring.
PARTS INFORMATION
Refer to CAPS or the parts catalog microfiche for power window motor and regulator part numbers.
WARRANTY INFORMATION
Standard warranty procedures and policies apply. The Labor Operation Time Schedule (LOTS) manual has the correct labor operation number and time information for each model covered by this bulletin. Refer to the LOTS manual when replacing a power window motor an/or regulator on a vehicle which is still within the warranty period.