DIY Network

Window & Door-Lock Upgrade -- Power-Window and Lock Assemblies From "Weekend Mechanic" episode WKM-108

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Figure A Figure B Figure C Figure D Figure E Figure F Figure G Figure H Figure I Figure J Figure K

With the door panel and old manual window-regulator removed, the next phase of the project is the installation of the power-window and power door-lock assemblies.

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.



Power-Window Assembly


The old window-lift assembly (figure A) utilized a manual drive mechanism, small gear, large gear and lever that attaches to the window track.

By contrast, the new assembly (figure B) is more robust, and utilizes a reversible electric-motor which operates the gears and lever that, in turn, raise and lower the window.

• To install the new regulator, carefully raise the window glass by hand. You can secure the glass temporarily with duct tape to keep it out of the way during the installation.
  
  
  
  
• With the glass secured, carefully work the new regulator assembly through the opening in the door (figure C), making certain that it is oriented in the right direction.

  Tip: To simplify the installation, it may be helpful to connect the regulator wiring before installing the regulator assembly in the door. Check the instructions that come with your kit for proper wiring procedures.

  Tip: If you happen to have a work-light, using it will help make it easier to work inside the door.
  
  
  
  

• Lower the window slightly so that you can fit the end of the lifting arm into the window track (figure D).
  
  
  
  
• It may take some effort to work the regulator into position, placing it so that the studs that secure it come through the original attachment holes where the old, manual one attached.
  
  
  
  
• With the studs in place, secure the assembly with nuts.

  Note: If you're installing a universal kit, you may need to drill new holes in the metal door panel for securing the assembly with bolts and nuts.

• To secure the power-lock assembly, use the assembly as a template (figure E) to mark the locations of the holes you'll need to drill for mounting the assembly.
  
  
  
  
• With the locations marked, drill your holes in the metal door panel using a cordless drill and drill-bit designed for drilling metal.
  
  
  
  
• Unlike the regulator we installed, the lock assembly is a universal design, so some minor modifications are necessary to achieve a perfect fit on this particular truck. The rod that attaches the auto-lock mechanism to the lock-button must be cut to the necessary length and bent to the proper configuration (figure F).
  
  
  
  
• The end of the rod attaches to the lock-button with a specialized fastener (figure G).
  
  
  
  
• The fastener attaches to the rod using set-screws so that it can be adjusted to the proper height (figure H). Once installed inside the door, the auto-lock motor pushes the rod upward, which in turn pushes up the lock-button to unlock the door. The reverse action locks the door.
  
  
  
  
• In order to ensure that the fastener and positioning of the rod can be adjusted later if necessary, an access hole should drilled in the metal door-panel at the location of the fastener. Measure and mark the location where the fastener will be located (figure I).
  
  
  
  
• Drill an access hole in the metal door panel using a cordless drill and drill-bit designed for drilling metal (figure J).

  Tip: To keep the bit from slipping, dent the door with a center-punch before drilling.
  
  
  
  

• With the rod bent to the proper positioning, and the access hole drilled, the power door-lock can be positioned inside the door for installation (figure K). Position the assembly in the door and maneuver it so that the rod hooks onto the bottom of the lock button.
  
  
  
  
• Secure the assembly with the screws provided, and tighten down the Allen screws that attaches the rod to the lock button.

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