Generally, most of the things that go wrong with my car (such as key
locking mechanisms and door lock mechanisms) are things where I need
the original parts, and a local repair garage specializing in Saabs
manages to fix the problem (insert large amounts of money).
However, the rear window regulator (raise/lower mechanism for those
who haven't had to replace one) broke.
The mechanism has a small carrier that runs on a vertical brace that
attaches to the window glass itself. The motor drives a drum which
pulls a steel cable over a top pulley to pull up the window, and when
run in reverse, using a lower pulley, pulls down the window.
In the two scenarios I've seen myself, the top pulley (made of durable
precision machined plastic) shatters due to stress and temperature.
Insert at least $150 for the mechanism, hoping the motor is good, and
then we see if the garage puts it in or we do.
This actually devolved into two scenarios, one on a 1989 Ford Probe GT
(really liked that car despite the numerous problems). That got
replaced by a screen door roller (ball bearings) that had the right
diameter. Drill out the swaged in center and put a 1/4-20 bolt in,
using locktite, and you're ok.
2007 Saab 9-3... mostly GM-ized (another discussion entirely).
Regulator is available, maybe, sometime in December, at least 200
dollars (without motor which was OK), and then another 100 dollars in
shop time to put it in. Same plastic upper pulley.
Solution: make replacement pulley from aluminum. Drill out swaged
post that held the original plastic in place. Construction was swaged
post, bracket, spacer, pulley.
Make swaged shaft from steel to fit spacer. Assemble post, pulley,
and spacer onto bracket. Pound the heck out of the swaged post to
fasten it in place. (note to self, thinner wall might be better).
Take steel cable and get rid of kinks made by previous pulley breaking
(straighten with pliers, compressing cable. hope that no strands
break). Watch YouTube video showing how to manage to get the cable
strung on something different, but it involves oddly shaped green
pulley that was designed for restringing.
Install in car, making sure that pulley is lubricated, and that window
sled moves up and down properly.
Put door back together.
Call local Saab service people to see if they can reset "Alarm system
failure" because the car was run with the locking mechanism removed.
They can.
Promise to show local people how to fix this and what they might need
for a lathe if they decide to go this way.
Save several hundred dollars in not-available parts and shop fees.
Enjoy adult beverage in celebration.
Harvey
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Posted by: Harvey White <madyn@dragonworks.info>
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