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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| G500 Window regulators, findings and DYI improvements
It was time, the rear door panel clips where not holding as they should and needed to be replaced, while I’m at it, I’ve choose to dive into these PITA window regulators that MB uses in the G class, just to see if they can be improved upon.
Although I haven’t had one break as of yet, the idea that it will happen at any moment is ridiculous! I started to fear the toll plaza in the middle of winter, during a downpour or a parking garage and of course, long distance vacations. I guess the only reason it hasn’t happened to me, is because the truck isn’t our daily drive, window usage was minimized. Anyway the fear had to be understood better or removed if possible, IMO!
I made the choice to “fix the regulators before they break”, as I do not know if the cables are reusable once the motor has a chance to twist it up, kinking the hell out of them?
Thank to Silver-G500 here on P3, Who sent me his destroyed regulator. It gave me a chance to view all aspects closely and order some DIY parts I felt might fit the bill. The first thing I’ve noticed, once the panel’s where removed, was how “violated” all the screws associated with regulator removal looked! Not surprised though, I am the third owner of this truck. But what it does indicate is, these regulators have been replaced many times already! There has to be a better solution, if only to help preserve all the surrounding panels and parts from being removed time and time again unnecessarily, by more monkeys!
Upon removal, I see differences between my two rear windows regulators.
One side had the “original version,” thin plastic, cable roller guide. The other had a more robust plastic “newer version?” cable roller guide.
You can see it has an extra rib and thickness, added to the newer version roller guide in the photo.
Not only is newer version ribbed concentrically, giving it a 3/4” contact surface but it’s slightly thicker between all ribs and contains a larger washer like center pin, with a larger shaft, that is staked into place.
Whereas the old design had a 3/8” contact surface.
Surely the beefy roller is far superior and I would think it may last many years over the original version, time will tell.
Although I removed both rear regulators and discovered one side had the newer version, I wasn’t about to put it back without knowing how long it’ll last, moving forward, I’m sticking to my plan!
Looking closely at how the slide and cable system works, it’s easy to see what causes the plastic roller to fail so quickly.
The way I see it, the closer the glass pane lift mechanism comes to the upper roller, the further the cable is misaligned with the roller (I can only speak to the rear regulators as I have yet to do the fronts), pulling hard to one side of the roller and holding it under tension every moment the window is closed. After a while of non use or extreme heat, the roller begins to slowly take on this new position of leaning. I believe every time the window is lowered the cable becomes slackened against the roller of a brief second, as the bottom roller works to pull the window down, against the weather seal. When the window is raised again, the lift roller doesn’t land in the exact position as before and is now being forced to lean in a different direction, over and over. Until a crack develops and allows the cable groove to become misaligned/interrupted. As you can see in the photo.
That said, this is what I came up with as a fix.
Note my roller is thicker than stock, Nylon outer with a ball bearing center. At first I thought it might create some clearance issue, it does not. What is better about its width, it does hold the leaning cable inline better with the lift mechanism. The groove is deeper than stock, not a problem as the cable ends near the motor are spring loaded to absorb slack. I’ve decided to tighten up the cable a tad anyway, by relocating the cable end retainer nearest the roller by one notch.
I’ll work on a step by step later and only if there’s an interest. It’s a lot of work for me to sit and type, you know ADD thingy!
Enjoy
 (1Old and new roller.jpg)
 (2Cable roller.jpg)
 (3Window regulator fix copy.jpg)
 (4Door panel clips.jpg)
 (5Roller kit.jpg)
 (6roller up close.jpg)
 (7rivet.jpg)
 (8Metal vs nylon.jpg)
 (9Window regulator fix copy2.jpg)
 (10DYI begins.jpg)
 (11assembly copy.jpg)
 (12punch set.jpg)
 (13finished.jpg)
Attachments
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 1Old and new roller.jpg (86KB - 5 downloads)
2Cable roller.jpg (60KB - 2 downloads)
3Window regulator fix copy.jpg (119KB - 3 downloads)
4Door panel clips.jpg (58KB - 1 downloads)
5Roller kit.jpg (105KB - 1 downloads)
6roller up close.jpg (90KB - 1 downloads)
7rivet.jpg (42KB - 2 downloads)
8Metal vs nylon.jpg (66KB - 2 downloads)
9Window regulator fix copy2.jpg (139KB - 1 downloads)
10DYI begins.jpg (169KB - 1 downloads)
11assembly copy.jpg (104KB - 1 downloads)
12punch set.jpg (43KB - 1 downloads)
13finished.jpg (179KB - 1 downloads)
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: G500 Window regulators, findings and DYI improvements
I still have more to learn about posting images in order.
Is it possible to insert an image between text? |
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| Re: G500 Window regulators, findings and DYI improvements
NHDave - 2/4/2015 3:49 PM
I still have more to learn about posting images in order.
Is it possible to insert an image between text?
Not using the Attach file after posting feature of the software. Sorry.
It can be done using HTML coding and an online photo library, but that can be iffy. |
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djdinaz
Extreme Veteran
Date registered: Jun 2007
Location: Arizona
Vehicle(s): 03 G55
Posts: 439
| Re: G500 Window regulators, findings and DYI improvements
Interesting...
What did you have to do for attaching the updated pulley to the existing frame? Any clearance issues on the backside where whatever holding the updated pulley sits?
I was thinking the along the same vein, in that, if I ever get another failure (it's always been the pulleys for me) I was going to pick up some stainless rollers, and some coated cable and see if it could be re-strung before picking up another replacement.
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: G500 Window regulators, findings and DYI improvements
Thank you Dutch
I now see that my images "need not" be posted to the extent of 1000 wide, way too big, sorry.
I suppose it might be better to break text segments and images into multi posts, with in a thread, if it helps?
I ask because I see others with text, placed between images for clarity.And that might be because I visit a couple sites. That said, P3 is always considered the final word in my problem searching.
Trying to do my best here for P3
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Fred V
Regular
Date registered: Apr 2014
Location: Green Mnts
Vehicle(s): 02 G500
Posts: 88
| RE: G500 Window regulators, findings and DYI improvements
Dave,
Am definitely interested. I have a 2002 and assume I'll have problems eventually. I'd love to be able to upgrade parts so as to avoid problems, same idea as replacing the stock plastic idler and tensioner pulleys with aluminum ones. |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| RE: G500 Window regulators, findings and DYI improvements
Fred V - 2/4/2015 9:42 PM Dave, Am definitely interested. I have a 2002 and assume I'll have problems eventually. I'd love to be able to upgrade parts so as to avoid problems, same idea as replacing the stock plastic idler and tensioner pulleys with aluminum ones. Hi Fred I Thought about metal rollers but bagged it. Wasn't sure if metal cable against metal rollers would generate a crunchy or clicking sound after a while? It's been a month so far, both rear windows now operate in silence and with authority, just as one would've expected from MB, from the start. I'll get working on part to consider and a detailed description. |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: G500 Window regulators, findings and DYI improvements
djdinaz - 2/4/2015 5:37 PM Interesting... What did you have to do for attaching the updated pulley to the existing frame? Any clearance issues on the backside where whatever holding the updated pulley sits? I was thinking the along the same vein, in that, if I ever get another failure (it's always been the pulleys for me) I was going to pick up some stainless rollers, and some coated cable and see if it could be re-strung before picking up another replacement. I chose the factory option, to stake the rollers in place.
 (IMG_3517.JPG)
Attachments
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IMG_3517.JPG (179KB - 3 downloads)
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gelenda
Veteran
Date registered: Mar 2012
Location: Great Bay, New Hampshire
Vehicle(s): '03 G500, '16 E63S AMG, '15 Grand Cherokee Diesel
Posts: 122
| RE: G500 Window regulators, findings and DYI improvements
When you say "updated version" do you mean this one?
 (window regulator.jpg)
Attachments
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window regulator.jpg (41KB - 0 downloads)
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sjtymko
G-Class Photo Host
Date registered: Apr 2006
Location: Canada, AB, Sherwood Park (Edmonton)
Vehicle(s): 2002 G500, 2009 B200
Posts: 511
| RE: G500 Window regulators, findings and DYI improvements
Hi Dave, I am definitely interested in this too. I have one noisy rear and one noisy front at the moment (and one newly replaced front). These things are definitely a ticking time bomb waiting for the most inopportune time to fail. Bothersome. Steve
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: G500 Window regulators, findings and DYI improvements
<p>Gelenda- Judging by the size of the rivets holding the rollers in place, I would say yes.</p><p>That is the updated front window regulator </p>
Edited by NHDave 2/6/2015 7:00 AM
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| RE: G500 Window regulators, findings and DYI improvements
sjtymko - 2/6/2015 12:00 AM Hi Dave, I am definitely interested in this too. I have one noisy rear and one noisy front at the moment (and one newly replaced front). These things are definitely a ticking time bomb waiting for the most inopportune time to fail. Bothersome. Steve
I'll get moving on a brief write up now. I was hoping to do the write up, with step by step photos when I work on the front windows. |
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atg
Veteran
Date registered: Nov 2014
Location: Los Angeles
Vehicle(s): 2005 G55, 1985 300tdt
Posts: 129
| Re: G500 Window regulators, findings and DYI improvements
I wondered what was failing in there. I think three of mine are on their ways out.
Look forward to the writeup. Failing that, if you can just post dimensions +/- a good online source for the rollers and pins used, that would help me assemble the relevant parts, which is half the battle.
Thanks,
Karl |
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atg
Veteran
Date registered: Nov 2014
Location: Los Angeles
Vehicle(s): 2005 G55, 1985 300tdt
Posts: 129
| Re: G500 Window regulators, findings and DYI improvements
Some guy on benzworld did a replace thread FYI. You could just post the rebuild bit.
https://drive.google.com/folderview?id=0B7k-bx3mPyMwTFhGcXc4TlpmWmM&... |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: G500 Window regulators, findings and DYI improvements
I'm almost finished with this. It's been hellish up here, with snow up to and way beyond the waazoo!
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| RE: G500 Window regulators, findings and DYI improvements
I did the write up, took me for ever! Hope it helps Enjoy
Edited by NHDave 2/25/2015 12:45 PM
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4x4abc
Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
| RE: G500 Window regulators, findings and DYI improvements
good job!
I have 2 new window regulators as"just in case" spares in the garage
maybe I'll upgrade them before I need them |
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Floobydust
Veteran
Date registered: Mar 2014
Location: Massachusetts, USA
Vehicle(s): 1995 E320 Cabrio, 2003 G500, 2000 SL500, 1980 TR8
Posts: 284
| RE: G500 Window regulators, findings and DYI improvements
Nice! I'm really glad you took the time to write it up. I think it is ridiculous to scrap such an expensive part for a $2 plastic wheel (for that matter, it was ridiculous to design such an expensive part with a $2 plastic wheel). I noticed that the plastic cable terminators are in good shape on yours, but mine had broken (yet another plastic part). I repaired them with bicycle brake cable adjusters as I post on that other forum (www.benzworld [dot] org/forums/g-class/2041089-finally-new-me-g-wagon.html#post9302274).
- FD
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| RE: G500 Window regulators, findings and DYI improvements
Floobydust - 2/26/2015 6:23 PM Nice! I'm really glad you took the time to write it up. I think it is ridiculous to scrap such an expensive part for a $2 plastic wheel (for that matter, it was ridiculous to design such an expensive part with a $2 plastic wheel). I noticed that the plastic cable terminators are in good shape on yours, but mine had broken (yet another plastic part). I repaired them with bicycle brake cable adjusters as I post on that other forum (www.benzworld [dot] org/forums/g-class/2041089-finally-new-me-g-wagon.html#post9302274). - FD Interesting Flooby!
I didn't know that part could fail. Do you think the cable terminator failed before the roller or did the roller failure lead to the failure of the cable terminator? If you look closely at this new regulator photo, the cable terminator has also been revised, along with the plastic roller. That said, it's still a plastic cable retainer and not no where near as robust looking as the old version?
Edited by NHDave 2/26/2015 8:03 PM
 (2Cable roller.jpg)
Attachments
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2Cable roller.jpg (60KB - 16 downloads)
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LucaB
Member
Date registered: Jul 2013
Location: Italy
Vehicle(s): G 400 cdi
Posts: 31
| Re: G500 Window regulators, findings and DYI improvements
do you need to remove the window regulator off the door?
can the roller be replaced without dismantling the whole thing? |
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