Repairing/Rebuilding Power Window Cables
Contributed by Amceaglenest member AMC lifer.
The main cause of failure is that it uses a braided/stranded cable inside a plastic housing. Over time, the metal cable rubs on the plastic where the unit bends. This causes gumming up & sluggish operation. After this comes complete cable breakage. The cable can be rebuilt fairly easy, provided that it has not too broken. To restore use to a cable, the following can be done.
1. Remove the cable assembly from the motor & regulator.
2. Using a Dremel or other small rotary cutting tool with a cutting wheel, cut the black plastic cable housing at both ends of the cable as they attach to the metal. Be careful not to cut the metal cable inside.
3. Cut lenghtwise down the black plastic housing. Now the housing can be removed from the cable.
4. Clean all of the gunk from the cable, there may already be strands of the cable broken. cut away any really loosely wound strands leaving as much intact as possible.
5. Clean out the cable housing of any loose material leaving a clean interior.
6. Slip the housing back over the cable. There is tension enough to allow the cable to close back up, but if you wish, you can tape it back with electrical tape the length of the housing. Leave the ends untaped.
7. Reinstall the cable on your prized possession.
The cable will now rotate freely from the housing & the binding does not reoccur. You could use the cable without the housing, but the cable will be very noisy when being used. The housing adds some stiffness to the cable preventing it from flopping around behind the door panel.