1993 CHEVROLET PLYMOUTH ACCLAIM gearbox

(4) Reverse battery leads (steps 1 and 2 above) and
window should now move. If window does not move,
remove motor. See below for motor removal from ve-
hicle. (5) If window moved completely up or down, motor
should be reversed one more time (reverse leads from
step 4) to complete a full window travel inspection.
GEAR AND PINION REPLACEMENT AND
LUBRICATION
The window glass and mechanism have been found
to move freely. The window motor works. But the
glass does not move up or down. The motor gear and
pinion will need to be replaced (Fig. 1).
When gear and pinion assembly is replaced in gear
box, lubrication of gear box, gear pinion and seal is
necessary. In the event there is no lubricant in gear box, fill
with MOPAR multi-mileage lubricant or equivalent.
Apply a liberal amount of lubricant to inside area of
seal marked A as illustrated in Fig. 1 and sealing
surface at center area of gear and pinion coupling.
Also lubricate center gear box shaft and worm gear.
MOTOR REPLACEMENT CONVENTIONAL
REGULATORS
The following procedure describes replacement of a
defective motor without removing window regulator
or detaching any window system components. This
method of motor replacement is not acceptable if any
of window system parts are loosened or removed from
door such as:
² Lift channels
² Up stops
² Tracks and pivot brackets
² Are already loose by deficiency
² Are to be loosened or removed from the door.
Then use method of repair where entire regulator
is removed from door (Fig. 2 through 9).
REMOVAL
(1) Raise window to full UP position and keep it
there at all times while replacing motor. If window is in
any position other than full UP and motor is separated
from spring loaded regulator, then regulator counterbal-
ance spring will tend to propel window upwards.
WARNING:PLACE A WINDOW BLOCK IN DOOR
THAT WILL POSITIVELY PREVENT WINDOW FROM
GOING DOWN. THIS ACTION WILL PREVENT IN-
JURY THAT COULD BE CAUSED BY INCORRECT
INSTALLATION OF COUNTERBALANCE SPRING
OR UPWARD MOVEMENT OF THE WINDOW.
(2) Disconnect wiring connector from motor which
is located about eleven inches from motor. (3) Remove three mounting screws that hold motor
gearbox to regulator. Remove third screw that se-
cures motor tie-down bracket to inner panel if so
equipped. There are three holes in inner panel which
provide access to three mounting screws that secure
gearbox to regulator (Fig. 2).
Fig. 1 Motor Lubrication
Fig. 2 Electric Motor MountingÐConventional Regulators
Fig. 3 Front Door Power WindowÐAA Body
Ä POWER WINDOWS 8S - 3

For AJ body vehicles, it will be necessary to reach
through opening in inner door panel and around be-
hind regulator to gain access to motor gearbox re-
taining screws.
Fig. 6 Power Window Four DoorÐAP Body
Fig. 7 Power Window ConvertibleÐAJ Body
Fig. 8 Power WindowÐAJ Body
Fig. 4 Rear Door Power WindowÐAA Body
Fig. 5 Power Window Two DoorÐAP Body
8S - 4 POWER WINDOWS Ä

(4) To remove motor from regulator, grip motor
housing and pull motor towards inner or outer panel,
depending on regulator type. Some rocking or twist-
ing action may be necessary to disengage motor from
regulator.
WARNING:DO NOT HAVE ANY HANDS OR FIN-
GERS IN SECTOR GEAR AREA WHERE THEY CAN
BE PINCHED BY SMALL MOVEMENTS OF REGULA-
TOR LINKAGE.
INSTALLATION
New motor gearbox retaining screw holes are not
threaded. It may be desirable to tap holes before at-
tempting assembly. (1) Install new motor on regulator by positioning
motor gearbox so that it engages regulator sector
teeth. (2) Position motor so that center post gearbox fits
into its pilot hole in plate. A slight rotational or
rocking movement may be necessary to bring three
motor gearbox screw holes into proper position. (3) Install three gearbox screws and one tie down
bracket screw, if applicable. Tighten to 5 to 7 N Im
(50 to 60 in. lbs.) torque. (4) Connect pigtail wiring harness connector.
(5) Remove window block.
(6) Actuate regulator with switch to verify satis-
factory operation.
BENCH REPAIR OF REGULATOR AND MOTOR
CONVENTIONAL REGULATORS
To repair or inspect the entire electric window reg-
ulator, remove from the door as follows:
REMOVAL
(1) Disconnect wiring connector from motor.
(2) Hold glass in the up position.
(3) Remove rivets and/or screws that hold regula-
tor and motor to inner door panel. (4) Maneuver regulator assembly by hand to disen-
gage the drive arm slider from the glass lift channel.
Remove from door.
REPAIR
If entire regulator is not being replaced, repair as
follows:
WARNING:REMOVE COUNTER BALANCE SPRING
BEFORE THE MOTOR IS REMOVED. IF IT IS NOT,
THE SPRING TENSION WILL CAUSE THE REGULA-
TOR ARMS TO CLOSE AS SOON AS THE MOTOR
IS REMOVED AND COULD SERIOUSLY INJURE
YOUR FINGERS .
(1) Remove regulator as described above.
(2) Secure regulator in vise to prevent sector gear
from rotating. (3) Remove counter balance spring.
(4) Remove three motor attaching screws and re-
move motor. (5) Inspect regulator for:(a) Sector gear teeth must not be broken or se-
verely worn. (b) All rivets and sliders must be securely at-
tached. (c) Parts must not be bent or cracked.
(d) Sector gear must rotate freely.
(e) Perform window lift motor test as described
above.
INSTALLATION
(1) Install motor and attach with three motor at-
taching screws. If installation of new motor is neces-
sary, it may be desirable to tap motor retaining
screw holes. (2) Install counter balance spring.
(3) Replace regulator in door by reversing Removal
steps 1, 2 and 3. (4) Regulators may be secured to door panel using
rivets or 1/4-20 X 1/2 screws and nuts.
MOTOR REPLACEMENTÐFLEX DRIVE
REGULATORS
REMOVAL
(1) Raise or lower window to the proper access hole
position and remove screw that attaches the flex rack
to the drive arm (Fig. 10). Hold the glass in that po-
sition. (2) Remove the regulator attaching rivets by
knocking out the rivet center mandrel and drilling
Fig. 9 Rear Door Power WindowÐAC, and AY Body
Ä POWER WINDOWS 8S - 5

(b) Manually lift the window upward with the
unriveted flex drive electric regulator still attached
until the screw can be removed. If more access is
needed, remove the two screws that hold the
T-track to the motor gearbox. This will allow re-
moval of the motor from the T-track.
(5) Remove two screws that fasten the motor gear-
box to the metal T-track. (6) Perform bench test.
BENCH TEST
(1) Connect positive (+) lead from test battery to
either of the two motor terminals. (2) Connect negative (-) lead from test battery to
remaining motor terminal. (3) The motor will now rotate in one direction.
(4) Reverse the battery leads and the motor should
now rotate in the opposite direction. (5) If the motor does not rotate in both directions,
replace the motor.
INSTALLATION
(1) Install new motor on T-track using No. 8-32 X
1/2 screws tighten to 4 N Im (40 in. lbs.) torque.
(2) Feed top of T- track into access hole and point
and rotate it towards the hinge pillar until regulator
motor is approximately horizontal. Then rotate regu-
lator in the opposite direction about a 1/4 turn and
line up bracket tab to inner panel slot. (3) Fasten regulator with the rivet sequence shown
in (Figs. 10 and 11). (4) Actuate the motor until the flex rack is visible
within the access slot. Attach the window and drive arm assembly to the flex rack with the screws.
Tighten screws to 4 N Im (40 in. lbs.) torque.
POWER WINDOW CABLE HOUSING/MOTOR
REPLACEMENTÐAC and AY Bodies
WARNING: REMOVAL OF THE WINDOW LIFT MO-
TOR FROM THE REGULATOR WILL CAUSE THE
ASSIST SPRING TO UNWIND RAPIDLY WITH THE
POTENTIAL OF CAUSING PHYSICAL INJURY. IF
THE WINDOW LIFT MOTOR REQUIRES REPLACE-
MENT, SEE REGULATOR REPLACE CABLE AND
DRUM IN THIS GROUP OF THIS MANUAL.
(1) Remove front door trim panel. Refer to group
23, Body. (2) Disconnect window lift plate from glass (Fig.
15).
(3) Disconnect window track from door.
(4) Disconnect window lift motor and drive cables.
(5) Disconnect electrical connections.
(6) Carefully remove window track, cables and lift
motor assembly from door. (7) For installation reverse above procedures.
MOTOR REPLACEMENT
(1) Refer to Front Door Window Regulator for re-
moval. (2) The door glass must be in the down position.
(3) Tape glass to door frame to hold glass in the up
position. (4) If the window is not in the full up position, re-
move only the motor from the door. (5) Remove nuts from motor and cable housing
(Fig. 16). (6) Make sure motor is facing you before separat-
ing motor from housing. (7) Using a flat tool slowly separate motor from
housing, making sure the cable drum under the mo-
tor stays in cable housing. When motor is fully sep-
arated the assist spring will be completely unwound
(Fig. 17). (8) Remove assist spring by releasing the tabs on
the opposite sides of the spring, do not remove spring
from its case (Fig. 18).
Fig. 14 Rear Door Power WindowÐAP Body
ART: 928s-3; SIZE (1) = 1-3/4h x 3-1/2w
Fig. 15 Cable and Housing/Motor
Ä POWER WINDOWS 8S - 7