Hi all, well only a month or so into ownership and hitting my "to do" list when lo and behold, the Driver side rear quarter window decided to play up. Searching through the forum and taking some really well prepared instructions that definitely go beyond the factory manual I was making great progress. One thing that the document I was using did not mention was that the Seat Belt assembly had to be removed to find the third bolt... I used the technique described to avoid removing the convertible top though it was still very tight. As it turns out I was not the first person to be in this area and a replacement regulator had been fitted (date code 2010 vs my vehicle being a 2003) - thinking it would be the pulley wires/plastic box at fault, I had purchased that ahead of time. It was. BUT, the way of failure meant it was all jammed up and had distorted the top plastic idler wheel. I've seen some after market repair service with a metal pulley at the top, but the regulator fitted to mine seems to be a one time fitment (not removable or replaceable without breaking out power tools. I've order a replacement (used) item online, but wondered if anyone here has had a go at replacing that top pulley/idler?

Distorted idler pulley on window regulator

 

Take a look at this post of rothwell's:
https://www.jaguarforums.com/forum/x...8/#post1710384

 

Thanks for that link - will be useful once I get the top pulley issue resolved for sure. I do wonder if it is easier to assemble the motor/spindle with the cables attached before attaching them to the connecting box rather than fiddling around with it and trying to get bolts in etc... I will give it a go and see what gives.

 

The top pulley is garbage. I sent mine out to powerwindowrepair.com and they installed a bulletproof metal pulley with bearing, on a sturdy metal shaft. This thing will outlast the car and has a lifetime warranty.

That worthless pulley is the only mechanism keeping the cable winding straight and true on the spindle. But the bushing wears, the pulley doesn't run true, and the wire tangles.

 

I'm going to have a go at replacing the pulley with a metal one with bearing myself. Ordered a roughly same size one from eBay - should arrive Monday. Will post how I get on.

 

Update on this project - it appears it was a success - replacement pulley was relatively straight forward given a Dremel and some patience. I did notice that the window had been repaired before and that the crucial nylon slide was missing in the center section (under the white box) which no doubt contributed to its subsequent re-failure. The pulley/bearing was described as "U Groove Sealed Ball Bearing 6.4x38x8.3mm Wire Rope Track Guide Pulley" ($13) and I used a pan head 5mm bolt/nut (from my collection) arrangement to secure it along with a new wire kit ($16) so overall a cheap repair and one that will hopefully last. This window is way smoother running up and down now.

New pulley in position - center glide where the white wire junction box goes was missing the nylon washer/glider.