Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Door Glass and Regulator

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REMOVAL & INSTALLATION



Window regulators are riveted to the door frame. The rivets must be drilled out and replaced by bolts or bolt/nut combinations of certain specification. Read through the procedure and make sure all parts are on hand before beginning work.

1988-90 LeBaron Sedan
FRONT DOOR
  1. Lower the glass all the way. Remove the trim panel as described earlier.
  2.  
  3. Gently pull the air and water shields off the door.
  4.  
  5. Remove the three nuts that attach the glass to the regulator channel. Then, lower the glass all the way.
  6.  
  7. Remove the outer glass-sealing weatherstrip by disengaging the spring clip tabs from the slots in the outer door panel. To do this, grasp the weatherstrip between the thumb and forefinger on either side of each spring clip. Pull out slightly and then up at each clip until the weatherstrip is free.
  8.  
  9. Work the glass off the mounting studs and remove it through the slot in the top of the lower door.
  10.  
  11. To remove the regulator, drive the center pin of each regulator mounting rivet out with a hammer and drift punch. Then, drill the rivets out with a 1 / 4 in. (6mm) drill.
  12.  
  13. Disengage the regulator arm from the lift plate and then remove the regulator through the access hole in the inside of the door.
  14.  

To install:
  1. Load the new regulator it through the access hole and engage the access arm with the lift plate. Then, bolt the regulator to the door with 1 / 4 -20 nuts and short screws, making sure these screws will not interfere with regulator operation. Tighten the screws and nuts to 90-115 inch lbs. (10-13 Nm).
  2.  
  3. Install the new glass by lowering it into the door. Position the glass on the mounting studs.
  4.  
  5. Install the outer weatherstrip by sliding the clips into the door panel slots and sliding them downward until they lock.
  6.  
  7. Raise the glass to the top of its travel, then loosely install the three retaining nuts. Seat the glass fully in the upper glass run to adjust it, and then tighten the mounting nuts gently.
  8.  
  9. Install the air and water shields and the trim panel as described earlier in this section.
  10.  

REAR DOOR

See Figures 1 and 2

  1. Remove the trim panel as described earlier in this section.
  2.  
  3. Remove the water shield and air shield. Remove the end seals from the front and rear of the door at the belt line.
  4.  
  5. Remove its two mounting bolts and remove the support bracket from underneath the fixed glass at the rear of the door.
  6.  
  7. Remove, from inside the door, the two brackets that attach the "division'' channel (dividing the moveable and stationary glass sections).
  8.  
  9. Remove the glass run weatherstrip from the forward and top edges of the door where the moveable glass contacts it.
  10.  
  11. Remove the mounting screw from the top of the division channel.
  12.  
  13. Remove the fixed glass.
  14.  
  15. Remove the outer glass-sealing weatherstrip by disengaging the spring clip tabs from the slots in the outer door panel. To do this, grasp the weatherstrip between the thumb and forefinger on either side of each spring clip. Pull out slightly and then up at each clip until the weatherstrip is free.
  16.  
  17. Remove the bolt (it has a shoulder on it) which attaches the glass to the drive arm of the flex drive mechanism.
  18.  
  19. Remove the division channel, moveable glass and drive arm together by raising the assembly. Rotate it 90 degrees, so the lower division channel bracket is parallel to the opening. Then, lift the assembly out through the belt opening.
  20.  
  21. Drive the center pins from the 6 mounting rivets (7 with electric windows) from the regulator using a hammer and drift pin. Then drill the rivets out with a 1 / 4 in. (6mm) drill. Then, rotate the regulator as necessary for clearance and remove it through the access hole in the door.
  22.  



Click image to see an enlarged view

Fig. Fig. 1: Rear door component locations



Click image to see an enlarged view

Fig. Fig. 2: When tightening the regulator mounting bolts, make certain to follow the numerical sequence as shown

To install:
  1. If reusing the same regulator, clean and lubricate the flex drive teeth. Then, orient the regulator so it can be installed through the access hole and locate it inside the door with its locating tab engaging the appropriate hole.
  2.  

The tightening sequence specified for the following step must be followed to prevent binding of the flex drive unit for the window.

  1. Use 1 / 4 -20 bolts and nuts to remount the regulator, tightening the nuts as specified in the illustration. Tighten to 90 inch lbs. (10 Nm).
  2.  
  3. To install the new glass, start the bottom of the division channel, the glass, and the drive arm assembly into the belt opening. With the lower bracket parallel to the opening, lower the assembly into the door until the upper division channel bracket is near the belt opening.
  4.  
  5. Rotate the assembly 90 degrees to bring it into its normal orientation. Then, rest the channel on the bottom of the door.
  6.  
  7. Raise the glass by hand. Then, position the drive arm onto the flex drive and secure it with the bolt with the shoulder on it.
  8.  
  9. Install the outer glass-sealing weatherstrip.
  10.  
  11. Install the fixed-glass bracket, but do not tighten the bolts. Then, position the fixed-glass into the opening and rock it into position. Allow it to rest lightly on the support bracket.
  12.  
  13. Fit the rear edge of the division channel over the front edge of the fixed-glass. Then, install the mounting screw into the top of the division channel.
  14.  
  15. Install the glass run weatherstrip into the forward and top door channels.
  16.  
  17. Install the upper bracket retaining the division channel. Then, install the lower bracket retaining the division channel.
  18.  
  19. Push the fixed glass bracket upward and secure it in place.
  20.  
  21. Install the end seals at the belt opening. Install the air and water shields.
  22.  
  23. Install the door trim panel as described earlier in this section.
  24.  

1990 Daytona


CAUTION
If the glass has shattered, wear gloves and work cautiously. Use a protective, heavy cloth to cover all painted surfaces, plastic parts, and interior trim near the glass. Remove the glass from the window frame before removing the gloves.

  1. Roll the window all the way down.
  2.  
  3. Disconnect the battery.
  4.  
  5. Remove the trim panel and air and water shields as described earlier in this section. Then, raise the glass until it is possible to work on the glass mounting nuts through the lower access hole (reconnecting the battery temporarily to operate the window motor, if the car has electric windows).
  6.  


WARNING
If the glass is still in position, make sure to support it during the next step.

  1. Remove the three lift plate-to-glass attaching nuts.
  2.  
  3. Remove the two glass stabilizers. If the glass is intact, remove it through the window frame.
  4.  


CAUTION
If the glass has been shattered, wear gloves/goggles and use a heavy duty shop-vacuum to carefully remove all glass particles from the door and glass run at this point.

  1. Remove the lift plate-to-regulator screw and remove the lift plate from the door.
  2.  
  3. Using a hammer and drift punch, drive out the center pin in each of the 8 rivets (7 on cars with electric windows) that mount the regulator to the door. Then, drill out each rivet with a 1 / 4 in. (6mm) drill.
  4.  
  5. Turn the regulator as necessary and then remove it through the access hole in the door.
  6.  

To install:
  1. Remove the flex window drive and install it onto the new regulator. Clean and lubricate the teeth.
  2.  
  3. Work the assembly back into the door through the access hole, and position it so its mounting holes line up with the holes where rivets where installed. Install 1 / 4 x20 bolts and corresponding nuts to mount the regulator. Tighten the bolts to 90 inch lbs. (10 Nm).
  4.  
  5. Attach the lift plate to the regulator with an M6x25 bolt.
  6.  
  7. Attach the three glass-to-lift plate mounting studs to the new glass. Then, install the glass through the window opening. It must initially be cocked to the rear to work it into position and then leveled. Install the retaining nuts without tightening them.
  8.  
  9. Attach the two inner stabilizers without tightening them. Then, loosen the three glass track mounting screws.
  10.  
  11. Connect the battery if the car has electric windows and install the crank handle if it has manually operated windows. Then, guiding the glass, move the window up carefully until it has reached its uppermost position.
  12.  
  13. Tighten the three lift plate-to-glass attaching nuts, starting with the one in the middle, to 85 inch lbs. (9 Nm).
  14.  
  15. Tighten the three glass track mounting screws to 115 inch lbs. (13 Nm).
  16.  
  17. Adjust the inner glass stabilizers so they just touch the glass and then tighten them to 115 inch lbs. (13 Nm).
  18.  
  19. Lower the glass and disconnect the battery or remove the window regulator handle. Install the door trim panel as described earlier in this section.
  20.  
  21. Connect the negative battery cable.
  22.  

1988-90 Models Except Daytona, LeBaron Sedan, Premier and Monaco

FRONT DOOR WITH MANUAL REGULATOR

A special tool must be used to remove the glass, or the glass-run channel may be damaged. Use Miller Tool No. C-4867 or equivalent.

  1. Remove the door trim panel as described earlier. Carefully remove the water shield as described there also.
  2.  
  3. Lower the glass to gain the best possible access to the rear glass sliders. Then, use the special tool to disengage the sliders from the rear glass guide, holding the glass to keep it from rotating and falling.
  4.  
  5. Rotating the glass on the regulator roller, slide it rearward and lower the rear until it reaches a 45° angle. Then, remove it.
  6.  
  7. Temporarily install the regulator handle and set the position of the unit for easy access to the regulator mounting rivets (just below the position where the window would normally be all the way up).
  8.  
  9. Drill out the three rivets on the regulator with a 1 / 4 in. (6mm) drill. Then, slide the regulator off the glass lift channel. Cock the regulator to an appropriate angle and remove it through the access hole.
  10.  

To install:
  1. Angle and position the regulator appropriately and work it through the access hole in the door.
  2.  
  3. Line up the regulator mounting and rivet holes and then install short 1 / 4 -20 bolts and nuts (it may be easier to install the bolts if you reset the position of the regulator by temporarily installing the handle). Tighten the bolts to 90-115 inch lbs. (10-13 Nm) and make sure they are short enough so that they will not interfere with the moving parts as the window is raised and lowered.
  4.  
  5. Transfer the lift channel and sliders to the new glass. Then, slide the glass back into the door at the angle at which it was removed.
  6.  
  7. Rotate the glass to its normal position and slide it forward on the regulator roller in reverse of the removal procedure.
  8.  
  9. Position the glass for best possible access to the rear sliders, holding it to keep it from rotating and falling. Then, use the special tool to engage the sliders with the rear glass guide.
  10.  
  11. Install the water shield and trim panel as described earlier in this section.
  12.  
  13. Connect the negative battery cable.
  14.  

FRONT DOOR WITH ELECTRIC REGULATOR

A special tool must be used to remove the glass, or the glass-run channel may be damaged. Use Miller Tool No. C-4867 or equivalent.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the door trim panel as described earlier in this section. Carefully remove the water shield as described there also.
  4.  
  5. Lower the glass (temporarily attach the battery cable) to gain the best possible access to the rear glass sliders. Then, use the special tool to disengage the sliders from the rear glass guide, holding the glass to keep it from rotating and falling.
  6.  
  7. Rotating the glass on the regulator roller, slide it rearward and lower the rear until it reaches a 45° angle. Then, remove it.
  8.  
  9. Adjust the position of the regulator until there is access to all the regulator mounting rivets (this is just below the position where the glass is all the way up.
  10.  
  11. Disconnect the negative battery cable. Then, detach the window motor electrical connector.
  12.  
  13. Drill out the 6 regulator mounting rivets with a 1 / 4 in. (6mm) drill. Then, slide the regulator off the glass channel.
  14.  
  15. Remove the motor from the regulator. Then, remove the regulator from the door, turning it as necessary so it will fit easily through the access hole.
  16.  

To install:
  1. If the regulator is being re-used, clean and lubricate the teeth on the flex drive rack. Then, load the regulator assembly through the door access panel.
  2.  
  3. Install the motor onto the regulator. Then, engage the regulator roller with the lift channel.
  4.  
  5. Line up the regulator mounting and rivet holes, then install short 1 / 4 -20 bolts and nuts (it may be easier to install the bolts if you reset the position of the regulator by temporarily installing the handle). Tighten the bolts to 90-115 inch lbs. (10-13 Nm) and make sure they are short enough that they will not interfere with the moving parts as the window is raised and lowered.
  6.  
  7. Attach the regulator wiring connector and the negative battery cable.
  8.  
  9. Transfer the lift channel and sliders to the new glass. Then, slide the glass back into the door at the angle at which it was removed.
  10.  
  11. Rotate the glass to its normal position and slide it forward on the regulator roller in reverse of the removal procedure.
  12.  
  13. Position the glass for best possible access to the rear sliders, holding it to keep it from rotating and falling. Then, use the special tool to engage the sliders with the rear glass guide.
  14.  
  15. Install the water shield and trim panel as described earlier.
  16.  

REAR DOOR WITH MANUAL REGULATOR

Follow the previous front door with manual regulator procedure, noting that there are only 3 or 4 mounting rivets for the regulator assembly.

REAR DOOR WITH ELECTRICAL REGULATOR

Follow the previous front door with electric regulator procedure through Step 4. Remove the regulator-to-regulator arm bolt; then proceed with the remaining steps of the procedure. Note that the rear door electric window regulator is retained by only 5 mounting rivets.

1991-95 Spirit, Acclaim, LeBaron Sedan, Sundance and Shadow

See Figures 3, 4 and 5

  1. Remove the door trim panel, silencer pad and water shield.
  2.  
  3. Position the door glass half way up pin the door glass opening.
  4.  
  5. Insert the door glass removal tool C-4867 (or equivalent) between the glass slide and channel retaining lip at approximately 2 in. (51mm) down from the top rearward corner of the glass. Push the handle of the tool toward the glass to open the channel. Push downward at the front of the glass to separate the slide from the channel.
  6.  
  7. Insert the door glass removal tool C-4867 (or equivalent) between the glass slide and channel retaining lip at approximately 2 in. (51mm) up from the bottom rearward corner of the glass through the opening in the inner door panel. Push the handle of the tool toward the glass to open the channel. Pull upward at the front of the glass to separate the slide from the channel. Do not allow the upper slide to snap back into the channel.
  8.  
  9. Rotate the front of the glass downward and slide the glass forward to separate the glass lift channel from the regulator lift arm roller.
  10.  
  11. Remove the door glass through the opening at the top of the door.
  12.  
  13. On vehicles with power windows, disconnect the negative battery cable.
  14.  
  15. Detach all electrical connectors from the power window motor, if applicable.
  16.  
  17. Remove the bolts holding the window regulator to the inner door panel.
  18.  
  19. Slide the roller from the window lift channel. Rotate the regulator to bring the lift arm through the access hole first.
  20.  
  21. Remove the regulator assembly from the door.
  22.  



Click image to see an enlarged view

Fig. Fig. 3: Special tool C-4867 or equivalent is needed to remove the window glass from the door



Click image to see an enlarged view

Fig. Fig. 4: The manual regulator is a simple gear type regulator



Click image to see an enlarged view

Fig. Fig. 5: The power window regulator is also a gear type regulator, but it driven by the power motor rather than the hand crank

To install:
  1. Position the regulator in the door in its original position, then install and tighten the regulator mounting bolts until snug. Make sure that the roller is situated in the window lift channel.
  2.  
  3. Connect the electrical wiring to the window motor, if applicable.
  4.  
  5. Lower the door glass into the opening at the top of the door.
  6.  
  7. Tip the rear of the glass downward and insert the window channel regulator arm roller into the glass lift channel, if not already done.
  8.  
  9. Guide the door glass into the glass run weatherstrip at the front of the door.
  10.  
  11. Push the top of the glass rearward to snap the top slide into the the glass run channel.
  12.  
  13. Push downward at the front of the glass to snap the bottom slide into the glass run channel.
  14.  
  15. Install the water shield, silencer pad and trim panel.
  16.  
  17. Connect the negative battery cable.
  18.  

1991-95 New Yorker, Dynasty, Imperial and Fifth Ave.

See Figures 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the door trim panel.
  4.  
  5. Remove the silencer pad and water shield.
  6.  
  7. Remove the side view mirror trim cover and door frame trim molding.
  8.  
  9. Remove the front door speaker.
  10.  
  11. Move the glass to the down position and remove the glass-to-lift plate fasteners.
  12.  
  13. Loosen the door glass slam bumpers.
  14.  
  15. Lift the glass upward through the opening at the top of the door.
  16.  
  17. Remove the nut holding the cable retainer to the inner door panel and slip the cables from behind the retainer.
  18.  
  19. Disengage the push-in retainer holding the cables to the inner door panel above the speaker on vehicles with power windows.
  20.  
  21. Remove the bolts holding the top of the glass lift bar to the inner door panel.
  22.  
  23. Remove the nut holding the bottom of the lift bar to the bottom panel of the door.
  24.  
  25. Remove the bolts holding the window crank regulator to the inner door panel on vehicles with manual windows.
  26.  
  27. Remove the nuts holding the motor and regulator to the inner door panel on vehicles with power windows.
  28.  
  29. Separate the window regulator and power motor, if applicable, from the door.
  30.  



Click image to see an enlarged view

Fig. Fig. 6: Manual window regulator orientation in the door unit



Click image to see an enlarged view

Fig. Fig. 7: The power window regulator is positioned the same as the manual type, but the power motor is mounted in the bottom of the door

To install:
  1. Position the window regulator and power motor, if applicable, in the door.
  2.  
  3. Install the nuts to hold the motor and regulator to the inner door panel on vehicles with power windows.
  4.  
  5. Install the bolts to hold the window crank regulator to the inner door panel on vehicles with manual windows.
  6.  
  7. Install the nut to hold the bottom of the lift bar to the bottom panel of the door.
  8.  
  9. Install the bolts to hold the top of the glass lift bar to the inner door panel.
  10.  
  11. Engage the push-in retainer to hold the cables to the inner door panel above the speaker on vehicles with power windows.
  12.  
  13. Slip the cables in behind the retainer and remove the nut to hold the cable retainer to the inner door panel.
  14.  
  15. Lower the glass down through the opening at the top of the door.
  16.  
  17. Tighten the door glass slam bumpers.
  18.  
  19. Install the glass-to-lift plate fasteners.
  20.  
  21. Install the front door speaker, if applicable.
  22.  
  23. Install the side view mirror trim cover and door frame trim molding.
  24.  
  25. Install the silencer pad and water shield.
  26.  
  27. Install the door trim panel.
  28.  
  29. Connect the negative battery cable.
  30.  

1990-91 TC by Maserati; 1991-95 Daytona, LeBaron Coupe and LeBaron Convertible

See Figures 8, 9 and 10

  1. Remove the door trim panel.
  2.  
  3. Remove the silencer pad and water shield.
  4.  
  5. Raise the door glass to 4 in. (10cm) above the down position.
  6.  
  7. Disconnect the negative battery cable, if the vehicle is equipped with power windows.
  8.  
  9. Loosen the bolts holding the glass stabilizers and guide hook receiver to the top of the inner door frame.
  10.  
  11. Remove the nuts holding the door glass to the lift plate.
  12.  
  13. Separate the glass from the lift plate and lift the glass upward from the opening at the top of the door.
  14.  
  15. Remove the bolts holding the regulator to the inner door panel.
  16.  
  17. Remove the nuts holding the lift plate to the glass.
  18.  
  19. Remove the regulator assembly through the access hole in the door.
  20.  



Click image to see an enlarged view

Fig. Fig. 8: Remove the window glass through the top opening in the door at a slight angle



Click image to see an enlarged view

Fig. Fig. 9: Familiarize yourself with the various components and their locations before dismantling the regulator from the door



Click image to see an enlarged view

Fig. Fig. 10: The electric power window regulator, as well as the manual regulator, should be removed through the access hole in the door

To install:
  1. Install the regulator assembly through the access hole in the door.
  2.  
  3. Install the nuts to hold the lift plate to the glass.
  4.  
  5. Install the bolts to hold the regulator to the inner door panel.
  6.  
  7. Lower the glass down through the opening at the top of the door, then install the glass to the lift plate.
  8.  
  9. Install the nuts to hold the door glass to the lift plate.
  10.  
  11. Tighten the bolts to hold the glass stabilizers and guide hook receiver to the top of the inner door frame.
  12.  
  13. Connect the negative battery cable, if disconnected.
  14.  
  15. Install the silencer pad and water shield.
  16.  
  17. Install the door trim panel.
  18.  

Premier and Monaco

  1. Remove the door trim panel and water shield.
  2.  
  3. Remove the belt line weatherstrip.
  4.  
  5. Remove the bolts holding the glass to the window regulator.
  6.  
  7. Remove the glass from the door by lifting it out of the glass opening at the top of the door.
  8.  
  9. Remove the nuts holding the regulator to the inner door panel.
  10.  
  11. Remove the screws holding the regulator gear to the inner door panel.
  12.  
  13. Disengage the tube from the retainer clip.
  14.  
  15. Remove the regulator from the door.
  16.  

To install:
  1. Remove the regulator from the door.
  2.  
  3. Disengage the tube from the retainer clip.
  4.  
  5. Remove the screws holding the regulator gear to the inner door panel.
  6.  
  7. Remove the nuts holding the regulator to the inner door panel.
  8.  
  9. Remove the glass from the door by lifting it out of the glass opening at the top of the door.
  10.  
  11. Remove the bolts holding the glass to the window regulator.
  12.  
  13. Remove the belt line weatherstrip.
  14.  
  15. Remove the door trim panel and water shield.
  16.  

 
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