How to repair Audi Window Regulators? Solution

[SJ]

I found a cheap solution for the broken nylon cable guides > a brass
plumbing part.
New Pictures and procedures are posted at   www.geocities.com/syljay47

The web site also has pix and procedure for removing and modifying a cable
pulley for the times when you need to replace the cable.

I'll write up a detailed procedure after I get more pictures made. The above
web site pix and explanations will be sufficient to help you fix a window
regulator.

Parts:
1/8" X 1/4" ID hose barb to MIP adapter(Watts A-85  PB225)
Electric tape
Electric shrink tubing
Bicycle spoke nipple

Procedure:
1. Remove cable stop using dremel tool, dont cut the cable! Just cut the end
stop.
2. Trim end of nylon cable spring guide
3. Drill hole in cable guide for brass adapter
4. Heat nylon guide with heat gun to soften a bit
5. Tap in barbed adapter . .you now have a fixed cable spring guide
6. Cable sleeve needs to be timmed by 0.150 to compensate for longer brass
adapter
7. Use electrical tape and shrink tubing to compensate cable sleeve for
larger brass adapter
7. Put everything back together. Use modified bicycle spoke nipple as cable
end stop. Crimp spoke in vice.

SJ

================================================

----- Original Message ----- 
From: "SJ" <syljay at optonline.net>
To: <quattro at audifans.com>
Sent: Sunday, March 05, 2006 12:55 PM
Subject: How to repair Audi Window Regulators?


> Problem:  How to remove the wire crimp at end of cable?  And how to crimp
on
> new cable crimp?
>
> See the pictures posted at    www.geocities.com/syljay47    for reference.
>
> I've repaired several window regulators(pix 1)  in my two audis. Most of
the
> time, the repair consists of freeing up a stuck motor. The motor insides
get
> rusty and seize up. The motor armature(rotating part) rusts and gets stuck
> to the magnets.
>
> The other common problem is that the nylon cable guides/spring
retainers(pix
> 3)  get broken and the cable then gets unraveled.
>
> The parts of the regulator are strung together like beads on a necklace
and
> the ends of the string(cable) have crimps(pix 4). You cannot remove any
> parts unless you remove a crimp from the end of the cable where the
damaged
> part is located.
> I have a spare cable guide from a junk regulator. but to use it I have to
> remove the cable crimp and then crimp on a new one.
> I can remove the present crimp using a dremel tool and gently grinding off
> the crimp.
> But how do I put on a new crimp? The new crimp has to be approximately
same
> size as the old one, otherwise it wont fit into the take-up spool. If the
> fit is close, a dremel tool will shape it to size.
> Any advice?
>
> SJ
> 85 Dodge PU, D-250, 318, auto
> 85 Audi 4k - - sold but still on the road
> 88 Audi 5kq
> 90 Audi 100q
>
>



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