| Window & Door-Lock Upgrade -- Door Disassembly |
From "Weekend Mechanic"
episode WKM-108 |
|
|
|
advertisement
|
In this episode, Weekend Mechanic, Bruce Bonebrake, installs a power-window, power-lock and keyless entry kit on a work truck. Features such as these are frequently expensive options on new vehicles. If you went the "no frills" route when you purchased your vehicle, or you have an older vehicle without plush amenities, you can still add these types of conveniences in the form of do-it-yourself kits.
DIY Difficulty Rating for Repair: This is a fairly straightforward and easy project for the weekend mechanic. The project should take about a full day, but we allotted two days so that we could take our time. We give it a difficulty rating of 2 on a 5-point intermediate-level scale. In a fully equipped shop with professional mechanics and diagnostic computers, the job would take about half a day.
Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There will also be variations among different various after-market kits. Always consult your vehicle's service manual when undertaking significant automotive repairs. Follow the procedures, diagrams and safety precautions that come with the kit you select.
In addition to standard auto-mechanic's tools like socket wrenches, pliers and screwdrivers (figure A), some of the specialty tools that will be needed for this project include a jig-saw, power drill and tools for electrical work such as wire strippers, nippers and soldering iron and electrical tape (figure B).
There are numerous power-window kits available, including universal kits that fit most vehicles and "direct fit" kits in which the manual assemblies are removed and replaced with a power assembly. For our project, we selected a kit that incorporates wiring harnesses and components for installing keyless entry in addition to power doors and locks (figure C).
Door Disassembly
- To begin the project, remove the interior door panels (figure D).
- Remove the fasteners that hold the manual window-cranks, and remove the cranks themselves.
- With the crank removed, move on to the fasteners for the panel itself. You'll need to detach any fasteners that hold the panel in place, which may include ordinary Phillips screws as well as recessed "blind screws" (figure E). Some screws may be hidden behind door-trim that may need to be carefully pried loose.
- Once the fasteners are all removed, carefully lift off the panel (figure F ) and set it asid. Use caution when unfastening and removing plastic door panels they are quite fragile, and may scratch or crack easily.
- Note that the panel is secured additionally from behind, using molded plastic hooks (figure G) that fit into slots in the door itself.
- With the panel removed, you'll also need to remove the dust barrier (figure H). Do not tear, destroy or discard the dust barrier as it will need to be put back on later.
- With the dust barrier removed, roll the window-glass up and secure it in place.
- For our project, some of the existing rivets that hold the stock window regulator mechanism in place needed to be drilled out and removed (figure I).
- With the rivets eliminated, the regulator can be carefully removed from the door (figure J).
- With the regulator removed, carefully lower the window glass back down into the door.
In the segment that follows, the power-lock assembly is installed.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
| 
)
)
)
)
)
)
)
)
)
)
