A4 (2001) Rear Window Regulator Replacement (lengthy)
08-26-2006, 05:35 PM
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A4 (2001) Rear Window Regulator Replacement (lengthy)
I replaced the driver's side rear passenger window regulator the other day after it refused to go all the way up, or down for that matter. I could not find a good procedure online, but followed Dan Larson's <a href="https://www.audiworld.com/tech/int45.shtml">Window Guide Replacemnt</a> procedure and used the Bently Manual.
I give this as advice and you're on your own if you attempt any repairs to your car.
What you'll need: Window Regulator (part no. varies by door location)
Torx sockets or wrenches:
T-25
T-30
T-45
Phillips-head screwdriver
Rivets (rivet gun) and/or nuts & bolts hardware (appropriate wrenches) for reinstallation
1. Remove interior door trim
a. First remove the two screws on either side at the top of the trim:
<img src="http://pictureposter.audiworld.com/110723/door01.jpg" border="0">
b. Remove the screw inside the hand grip:
<img src="http://pictureposter.audiworld.com/110723/door02.jpg" border="0">
2. Remove plastic insert and then the screw behind it. Be careful when removing the insert - use a screwdriver wrapped in a rag so as not to damage the trim.
<img src="http://pictureposter.audiworld.com/110723/door03.jpg" border="0">
3. Pull trim straight up and once it's clear of the door lock, pull toward you. Next, pull back the foam insulation and find the window switch, disconnect the switch and pull it out of the door:
<img src="http://pictureposter.audiworld.com/110723/door04.jpg" border="0">
4. At the bottom inside corner, pull back the foam again and find the blue electrical connection for the door light. Disconnect this.
<img src="http://pictureposter.audiworld.com/110723/door05.jpg" border="0">
5. Other interior connections:
a. This connects to the door release handle - you'll have to pull back the foam again after you've disconnect the window switch (see above) and pull this out. On re-installation make sure the hook POINTS UPWARD.
b. This is for the door lock - use a needle nose pliers to remove this from the plastic clip - be careful of the clip.
c. Electrical connection for the window motor. Disconnect.
d. Four Torx T-45 screws which hold the door component carrier to the door. Remove these. Watch for the shim on the interior lower screw - you need this for reinstallation.
<img src="http://pictureposter.audiworld.com/110723/door06.jpg" border="0">
6. Remove the door component carrier: Clear any remaining cables which may be connected by zip ties or clips and lieft straight up on the carrier - gently to avoid snagging any cables or wires. It comes right out.
7. The component carrier removed and we see the offending window regulator.
a. Unscrew the two Torx T-25 screws holding the window to the regulator. Remove the window by carefully sliding it out.
b. These four rivets will have to be drilled out. I started with a relatively small bit and the moved up to a 7/32" to remove the rivets.
<img src="http://pictureposter.audiworld.com/110723/window01.jpg" border="0">
As a sidenote, here we see the cable at the top of the regulator - notice it is not taunt and appears frayed in spots:
<img src="http://pictureposter.audiworld.com/110723/window02a.jpg" border="0">
8. Remove the window motor by taking out the three Torx T-30 screws.
<img src="http://pictureposter.audiworld.com/110723/window03.jpg" border="0">
See how the regulator cable is tangled and the wheel is caked in grease:
<img src="http://pictureposter.audiworld.com/110723/window04.jpg" border="0">
The motor with the wheel removed:
<img src="http://pictureposter.audiworld.com/110723/window05.jpg" border="0">
The motor with the cradle from the regulator removed (a new cradle and wheel are included with the new regulator):
<img src="http://pictureposter.audiworld.com/110723/window06.jpg" border="0">
9. Here is the new regulator installed. You will notice the two nuts at the bottom of the picture - I do not like rivets, and if I have to do this again in another 80k miles, I want to be able to take it apart! I used a 1/4" drill bit to enlarge the holes in the frame and regulator and then used an M6 hex screw, nut, washer and locking washer. There is one location in which you will have to use a rivet, you will know it...
The motor mounts back onto the cradle with the three T-30 screws.
<img src="http://pictureposter.audiworld.com/110723/window07.jpg" border="0">
10. The regulator installed, with window, from the other side.
<img src="http://pictureposter.audiworld.com/110723/window08.jpg" border="0">
11. Next, reinstall carrier and connect power to the motor and try the window switch. If this works, then reassemble the rest of the door trim and you're done!
I give this as advice and you're on your own if you attempt any repairs to your car.
What you'll need: Window Regulator (part no. varies by door location)
Torx sockets or wrenches:
T-25
T-30
T-45
Phillips-head screwdriver
Rivets (rivet gun) and/or nuts & bolts hardware (appropriate wrenches) for reinstallation
1. Remove interior door trim
a. First remove the two screws on either side at the top of the trim:
<img src="http://pictureposter.audiworld.com/110723/door01.jpg" border="0">
b. Remove the screw inside the hand grip:
<img src="http://pictureposter.audiworld.com/110723/door02.jpg" border="0">
2. Remove plastic insert and then the screw behind it. Be careful when removing the insert - use a screwdriver wrapped in a rag so as not to damage the trim.
<img src="http://pictureposter.audiworld.com/110723/door03.jpg" border="0">
3. Pull trim straight up and once it's clear of the door lock, pull toward you. Next, pull back the foam insulation and find the window switch, disconnect the switch and pull it out of the door:
<img src="http://pictureposter.audiworld.com/110723/door04.jpg" border="0">
4. At the bottom inside corner, pull back the foam again and find the blue electrical connection for the door light. Disconnect this.
<img src="http://pictureposter.audiworld.com/110723/door05.jpg" border="0">
5. Other interior connections:
a. This connects to the door release handle - you'll have to pull back the foam again after you've disconnect the window switch (see above) and pull this out. On re-installation make sure the hook POINTS UPWARD.
b. This is for the door lock - use a needle nose pliers to remove this from the plastic clip - be careful of the clip.
c. Electrical connection for the window motor. Disconnect.
d. Four Torx T-45 screws which hold the door component carrier to the door. Remove these. Watch for the shim on the interior lower screw - you need this for reinstallation.
<img src="http://pictureposter.audiworld.com/110723/door06.jpg" border="0">
6. Remove the door component carrier: Clear any remaining cables which may be connected by zip ties or clips and lieft straight up on the carrier - gently to avoid snagging any cables or wires. It comes right out.
7. The component carrier removed and we see the offending window regulator.
a. Unscrew the two Torx T-25 screws holding the window to the regulator. Remove the window by carefully sliding it out.
b. These four rivets will have to be drilled out. I started with a relatively small bit and the moved up to a 7/32" to remove the rivets.
<img src="http://pictureposter.audiworld.com/110723/window01.jpg" border="0">
As a sidenote, here we see the cable at the top of the regulator - notice it is not taunt and appears frayed in spots:
<img src="http://pictureposter.audiworld.com/110723/window02a.jpg" border="0">
8. Remove the window motor by taking out the three Torx T-30 screws.
<img src="http://pictureposter.audiworld.com/110723/window03.jpg" border="0">
See how the regulator cable is tangled and the wheel is caked in grease:
<img src="http://pictureposter.audiworld.com/110723/window04.jpg" border="0">
The motor with the wheel removed:
<img src="http://pictureposter.audiworld.com/110723/window05.jpg" border="0">
The motor with the cradle from the regulator removed (a new cradle and wheel are included with the new regulator):
<img src="http://pictureposter.audiworld.com/110723/window06.jpg" border="0">
9. Here is the new regulator installed. You will notice the two nuts at the bottom of the picture - I do not like rivets, and if I have to do this again in another 80k miles, I want to be able to take it apart! I used a 1/4" drill bit to enlarge the holes in the frame and regulator and then used an M6 hex screw, nut, washer and locking washer. There is one location in which you will have to use a rivet, you will know it...
The motor mounts back onto the cradle with the three T-30 screws.
<img src="http://pictureposter.audiworld.com/110723/window07.jpg" border="0">
10. The regulator installed, with window, from the other side.
<img src="http://pictureposter.audiworld.com/110723/window08.jpg" border="0">
11. Next, reinstall carrier and connect power to the motor and try the window switch. If this works, then reassemble the rest of the door trim and you're done!
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09-19-2007, 09:56 AM
#8
AudiWorld Super User
!!!! IMPORTANT NOTE IF YOU BOUGHT A NEW REGULATOR !!!!!
I was <B>un</B>pleasantly surprised to find the 3 holes for the window motor bolts <b>untapped</b>. Apparently, this was a bad batch. I ordered from GermanAutoParts but who knows how many parts places are using this particular source. So, just a heads up to check the holes before you start -- in case you need to go buy a tap! I ended up buying an ultra cheapo metric set from HarborFreight -- but it worked! It was an M6-.75 tap. Some pics:
NEW mounting plate holes for window motor bolts:
<img src="http://images29.fotki.com/v1034/photos/4/48510/1705981/IMG_2970-vi.jpg">
OLD part:
<img src="http://images27.fotki.com/v989/photos/4/48510/1705981/IMG_2971-vi.jpg">
Bolt and tap used:
<img src="http://images28.fotki.com/v1003/photos/4/48510/1705981/IMG_2977-vi.jpg">
Andy
NEW mounting plate holes for window motor bolts:
<img src="http://images29.fotki.com/v1034/photos/4/48510/1705981/IMG_2970-vi.jpg">
OLD part:
<img src="http://images27.fotki.com/v989/photos/4/48510/1705981/IMG_2971-vi.jpg">
Bolt and tap used:
<img src="http://images28.fotki.com/v1003/photos/4/48510/1705981/IMG_2977-vi.jpg">
Andy
03-16-2010, 04:05 PM
#9
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Join Date: Mar 2010
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I'm having the same problem with my windows. I removed trim and what not, and think I found the problem.
The white part in the attached image is broken. Does anyone know the name of the part, and where I can order it from?
Thanks and take care.
The white part in the attached image is broken. Does anyone know the name of the part, and where I can order it from?
Thanks and take care.
04-27-2012, 07:00 AM
#10
AudiWorld Senior Member
Rear Window Regulator Repair Clip B5 A4 (and C5 A6) - photos
I am stocking all available window regulator repair clips.
But so far have not found a manufacturer or source for the B5 A4 rear (ditto C5 A6 rear) clips.
I am getting frequent requests for the rear clips for the B5 A4 and C5 A6, I would like to try to source them.
If anyone has his rear regulator out, I would love to get detailed photos of the guide piece that connects the larger sheet metal piece to the rail (and allows it to glide up/down).
I could then try if my manufacturers can make the piece.
Also, any other (plastic) parts that frequently break or wear and are hard to find.
Example: The fasteners for the lower engine cover (‘belly pan’); they are often missing, and ECS for example wants a bunch of $$$ ($50 or so). I ordered a decent quantity and should have them in stock within the next few weeks.
PM, post or email me at info@regulatorfix.com
http://pictureposter.audiworld.com/110723/window01.jpg
But so far have not found a manufacturer or source for the B5 A4 rear (ditto C5 A6 rear) clips.
I am getting frequent requests for the rear clips for the B5 A4 and C5 A6, I would like to try to source them.
If anyone has his rear regulator out, I would love to get detailed photos of the guide piece that connects the larger sheet metal piece to the rail (and allows it to glide up/down).
I could then try if my manufacturers can make the piece.
Also, any other (plastic) parts that frequently break or wear and are hard to find.
Example: The fasteners for the lower engine cover (‘belly pan’); they are often missing, and ECS for example wants a bunch of $$$ ($50 or so). I ordered a decent quantity and should have them in stock within the next few weeks.
PM, post or email me at info@regulatorfix.com
http://pictureposter.audiworld.com/110723/window01.jpg