The passenger window on Little Reddy finally decided to stop working completely, and after copping a whinge from Fiona about how hot it was to drive with the windows up all the time, I was allotted some time to fix it. Bought a set of new cables from MX-5 Mania ($180) last Saturday and yesterday started the job. Everything went by the book ... except ...
The Phillips head screws on the regulator motor were held in with locktite, and I stripped the head on one of them. Solved that by cutting a slot in the head and removed it with a flat-head screwdriver.
The capstans on the cables were slightly too long to fit in the anchor. Solved that by filing them down to size.
You can never have too much grease right?
Here's the assembly all back together and ready to be re-fitted into the door.
Next I connected the wire harness back to the car to test it. The mechanism went down no problem, but refused to go up. Grrrr! I tested the window motor by running some wires from the car battery directly to the motor terminals. It worked! OK so that means the switch itself was dodgy. Checked the resistance on various switch settings and sure enough, was getting 10-15 ohms with the passenger switch in the down position (should be zero ohms). I opened up the switch to find lots of oxidation on the contacts. Gave them a clean with fine sandpaper, reassembled the switch, and the resistance was much better (~4-5 ohms). Still need a new switch but at least it works now.
Reassembled the passenger window, tested it again and thankfully all was well.
The driver's side window assembly was next to come out. The only glitch this time was when a tab on the plastic guide/cable stop block snapped off while reassembling it. I need to track down a replacement, but for now I held it in place with a nut and bolt. Works OK, but the bolt sticks out a bit and prevents the window from descending the last 20mm.
It's all back together now and works a treat. Along the way, I also replaced the gearshift rubber gaiter ($80) which had perished. The gear changes now have a bit more resistance to them and feel a lot smoother.
Oh and I also installed a new driver's side mirror to replace the one that
got squashed at Wakefield Park in October. I got it cheap from MX-5 Mania ($80) because it had a tiny scratch in the paint. See if you can spot it! Very happy with the result, except that the red outer ring mismatches the black ring on the original passenger side mirror. I like the slight fisheye on the mirror too.
After all this hard work, I had a quick drive over to Jamberoo. I'm loving the feel of the new front pads/rotors and brake fluid, plus the gear change is nicely refreshed. And of course, the windows go up and down like they should!