Clunking Noise In the Up/Down Motion of the Window Regulator

1. Remove front door trim panel on door where clunking noise is heard. (Refer to "Front Door Trim Panel" in the "Doors" section of the Body/Repair Service Manual.)

2. Cycle the window up and down several times, and observe the window regulator assembly mounting bolt heads. Look for movement of the window regulator assembly while cycling the window up and down. You may also see witness marks where the bolt heads have removed the ELPO coating from the door structure.

^ If movement or witness marks are present, proceed to next step.

^ If movement or witness marks are not present, check for possible loose parts that may cause a clunking noise when the window is raised or lowered, and repair as necessary.

3. Carefully remove the lower rear section of the water deflector to gain access to the window regulator mounting bolt heads.

4. Remove front door outer panel. (Refer to "Front Door Outer Panel" in the "Doors" section of the Body/Repair Service Manual.)

IMPORTANT:
The front side door insulator assembly is called the door sound deadener in the service manual.

5. Remove front side door insulator assembly. (Refer to "Door Sound Deadener Panel-Sedan/Wagon" in the "Doors" section of the Body/Repair Service Manual.)

6. If witness marks are present on door structure, loosen the window regulator mounting bracket bolts and partially remove the window regulator from the door structure. Apply 3M(R) WINDO-WELD Primer (Black) (P/N 08643) or equivalent, primer to exposed metal around the cutouts in the door structure where the mounting bolts sit. Allow primer to dry according to manufacturer's recommendations.

If witness marks are not present, proceed to step 8.

7. If removed in previous step, re-install window regulator.

IMPORTANT:
Some window regulator bolts may not tighten since the threads in the regulator mounting bracket may have become stripped out.

8. Tighten window regulator bolts.

Torque: 10 N.m (89 in-lbs)





9. From the outside of the door structure, install two washers (P/N 11500272) and a nut (P/N 21021167) to each window regulator bolt and tighten nut.

Torque: Nut 22 N.m (16 ft-lbs)

10. Install the lower rear section of the water deflector. Make sure there are no creases left around the door structure mounting surface. If creases are present, there could be water leaks and/or dust intrusion.

11. Install front door trim panel. (Refer to "Front Door Trim Panel" in the "Doors" section of the Body/Repair Service Manual.)

12. Install front side door insulator assembly. (Refer to "Door Sound Deadener Panel-Sedan/Wagon" in the "Doors" section of the Body/Repair Service Manual.)

13. Install front door outer panel. (Refer to "Front Door Outer Panel" in the "Doors" section of the Body/Repair Service Manual.)