So my rear window regulator went, crap! Window was stuck down and I needed it fixed ASAP. I couldn't wait until I ordered a new one on-line and the Audi dealership didn't have one in stock (which would have cost a fortune)

So I decided to rebuild it... can't be too hard, right?

Here's how I did it.

Following the directions here on the site for removal and replacement I pulled the unit out and discovered that the top pulley fell apart, so I decided to make another. I took some aluminum stock and turned a new pulley. Cleaned everything up and noticed one of the cable was frayed. So I made a new one and put everything back together.

Everything works perfect and it all cost under $10

Considering the time I put into it, it would have been cheaper to buy a new one... I just didn't have the time.

Here is a link to some pictures

A4 window regulator - Imgur

 

can you give me a more detailed walkthrough on how to make a new pully for my window? Like what kind of materials and tools. i have the same problem with my left rear window. the right side though just falls unless i put a screw through the hole in the middle.

 

Nice job Reckless!! I like that a lot.

 

I just used what I had laying around which was 1/8" thick aluminum stock. Since the pulley needed to be 1/4" thick I doubled it up and screwed the pieces together. I would have much rather had solid stock since I was afraid that the tension of the wire would force the pieces apart, but I used 4 screws and epoxy to hold it together.

The rest of the work was just using dremels and files to shape it to the right size. I did buy an 1/8" carbide die for the dremel to shape the grove. You can see in the pictures how I just used blocks to get the dremel and pulley blank to the exact position so I can just rotate it to make the cut at the right level.

It wasn't anything special, just looking at the problem and doing what worked.

 

I think I'm gonna give it a shot and see how well it works for me. thanks for the help