GM Astro/Safari 1985-1996 Repair Guide

Door Glass and Regulator

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Window regulator components and mounting


CAUTION
Always wear heavy gloves when handling glass to minimize the risk of injury!

Door Glass
  1. Lower the glass to the bottom of the door and remove the door trim panel.
  2.  
  3. Remove the door channel run assembly.
  4.  

Mask or cover any sharp edges that could scratch the glass.

  1. Slide the glass forward until the front roller is in line with the notch in the sash channel.
  2.  
  3. Disengage the roller from the channel.
  4.  
  5. Push the window forward, then tilt it up until the rear roller is disengaged.
  6.  
  7. Place the window in a level position, and raise it straight up and out of the door.
  8.  

To install:
  1. Install the window into the door.
  2.  
  3. Push the window forward, then tilt it up until the rear roller is engaged.
  4.  
  5. Engage the roller to the channel.
  6.  
  7. Slide the glass forward until the front roller is in line with the notch in the sash channel.
  8.  
  9. Install the door channel run assembly.
  10.  
  11. Lower the glass to the bottom of the door and install the door trim panel.
  12.  

Regulator
  1. Raise the window and tape the glass in the full up position using cloth body tape.
  2.  
  3. Remove the door trim panel and the door panel, then, using a 3 / 16 in. (5mm) bit, drill the head from the rivet.
  4.  
  5. Slide the regulator forward and then rearward to disengage the rear roller from the sash channel. Then disengage the lower roller from the regulator rail.
  6.  
  7. Disengage the forward roller from the sash channel at the notch in the sash channel.
  8.  
  9. Collapse the regulator and remove it through the access hole in the door.
  10.  
  11. Lubricate the regulator and the sash channel and regulator rails with Lubriplate® or its equivalent.
  12.  

To install:
  1. Collapse the regulator and install it through the access hole in the door.
  2.  
  3. Engage the forward roller to the sash channel at the notch in the sash channel.
  4.  
  5. Slide the regulator forward and then rearward to engage the rear roller to the sash channel. Then engage the lower roller to the regulator rail.
  6.  
  7. Install the door trim panel and the door panel.
  8.  

Power Window Regulator
  1. Remove the negative battery cable.
  2.  
  3. Remove the door trim panel.
  4.  
  5. Remove the armrest bracket and water deflector.
  6.  
  7. Raise the window and tape the glass in the full up position using cloth body tape.
  8.  
  9. Remove the wiring harness from the regulator motor.
  10.  
  11. Remove the regulator to door rivets, using a 3 / 16 in. (5mm) bit to drill the heads from the rivets.
  12.  
  13. Slide the regulator forward and then rearward to disengage the rear roller from the sash channel. Then disengage the lower roller from the regulator rail.
  14.  
  15. Disengage the forward roller from the sash channel at the notch in the sash channel.
  16.  
  17. Collapse the regulator and remove it through the access hole in the door.
  18.  

To install:
  1. Lubricate the regulator and install through the access hole in the door.
  2.  
  3. Engage the forward roller to the sash channel at the notch in the sash channel.
  4.  
  5. Slide the regulator forward and then rearward to engage the rear roller to the sash channel. Then engage the lower roller to the regulator rail.
  6.  
  7. Install the regulator to door rivets, using 3 / 16 in. (5mm) rivets.
  8.  
  9. Install the wiring harness to the regulator motor.
  10.  
  11. Remove the tape from the glass.
  12.  
  13. Install the armrest bracket and water deflector.
  14.  
  15. Install the door trim panel.
  16.  
  17. Connect the negative battery cable and check operation.
  18.  

 
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