johnny quattro

I have an 04 B6 A4 1.8T quattro.

I have just ordered my fourth replacement driver front window regulator!
Four in 2 years!

This one is to replace an ECS supplied regulator that was installed end of October 2013 (lasted 3 months)!

ECS will replace the part under a manufacturers warranty after seeing photos of the failed part (if I pay $30 shipping again).

To take photos, I have to disassemble the door and remove the old part, so I will install another replacement while doing so.

Each time, I carefully followed the Audi service manual job installation instructions, with correct torques, etc.

Each one that has failed, is for the same reason. The wire has jumped the winder spool and become twisted and tangled.

I am getting really proficient doing this replacement for the wrong reasons!

Has anyone else had this repeated problem with window regulators?

Am I doing something wrong?

johnny quattro

Additional 2 cents worth!

After removal of my 4th failed regulator, I noticed that as well as the cable leaving the winding spool and becoming twisted, that 2 of the 3 motor mounting plastic posts had sheared (allowing the winding spool assembly to become loose).

My preventive solution to avoid a future repeat of this failure was to replace the 3 Torx T25 screws with 3/16" SS bolts, with washers and lock nuts.

After I had mounted and tightened the motor, I then removed each screw (one at a time) and drilled 3/16" down through the threaded post, thus allowing a bolt & lock washer to be inserted from the inside of the winder molding.
(see attached pics)

New regulator:
https://www.audiforum.ca/attachment....1&d=1391623690

Old regulator showing sheared posts:
https://www.audiforum.ca/attachment....1&d=1391623690

Sketch of post mod:
https://www.audiforum.ca/attachment....1&d=1391623690

A washer and lock nut now secures the motor mounting x 3.
Hopefully, this should prevent the posts from shearing in future!

sburns

How did this work out for you? I am now replacing my 3rd regulator, but I work in a machine shop and was looking to modify them somehow to last longer. This idea seems to be a good one.

Anyways, let me know how it worked out for you.

John Samuels

So far, so good!
I have removed the interior door trim panel to inspect the modified regulator replacement and everything looks secure.
No movement in the new winder, and no cracked posts.
It is an inexpensive, effective mod that corrects what was obviously an Audi design flaw.
When, and if the passenger side fails, I will do the same mod with the replacement regulator.
Go for it, as it will save you a ton of money! cheers:

sburns

So I ended up doing a mod of your mod. I drilled and tapped the posts thru for an 8-32 socket head cap screw so I wouldn't have to use a nut. You end up with the same result, but not fumbling around trying to line up a nut on the back of the regulator.

Check out the pics of my busted one being removed: https://www.dropbox.com/sh/04h8q1fk4...FYXHtcHda?dl=0

I bet I will never have to replace it again after this repair!

sburns

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John Samuels

Nice pix and I can really relate to them!

I like your mod better than my mod, but I could not do that as 2 of the 3 posts sheared on my regulator winder.

I had to drill through the remaining 1 post and the 2 sheared posts (these 2 are now effectively spacers), then fiddle to get the bolt through from the rear. Once through, a nylon lock nut and washer secured the winder once and for all!

As I said, if I could have done it your way, I would've!

The only risk you now have, is that if the winder works loose (and they do), your posts may also shear (I hope not)!

Great mod on mod! Thx for the info!