I got this wagon last week.  It’s rad.  Come for a ride in it and I’ll bore you to death talking about the fuel efficiency (I’m excited).  One small problem though, the passenger side window didn’t work. 

When I bought it the guy basically told me never to touch it.  Obviously I forgot this warning immediately, but it wasn’t a problem since I sit on the driver’s side.  But as soon as I had a passenger in it, which didn’t take long, their first instinct was to roll down the window.  Hot June, you know.  It stayed stuck in position, then fell into the door when someone slammed it.  Fortunately the glass wasn’t damaged, but it was stuck real good.  In BC where it’s like living in an aquarium for most of the year, it’s a problem.  Here’s how I fixed it. 

Tools:

Big Philips head

Small Philips head

Tire lever

Degreaser

Rag

Greaser

The door does not need to be removed from the hinges for this.  The main thing we’re going to do is clean the regulator and the rails. 

What Do

With thanks to Speed Hero for advice.  First step is to remove the door card.  There is a screw in door opener cup, one in the door closer cup, and one underneath the armrest.  They are all Philips.  The one under the armrest is pretty tough. 

Screws out, cups out, armrest off, carefullly!  It’s a million years old so don’t break it. 





Get that screw also.  Remove the regulator handle, (that’s the thing you turn to roll the window up and down).  There’s a C-clip holding it on.  Get a tiny screwdriver and pry it off, with your hand in the way to catch it because it will go flying all over the place.  If it lands in the grass you’ll never find it again. 

After the screws are removed, the door card is held on only by plastic buttons.  Start at the bottom corner and work your way around, making sure to wrap two fingers around each button as you pull it out.  You don’t want to be the jerk that rips a 30 year old cardboard door card. 

This is the vapor barrier.  If you’re really lucky, you’re the first person ever to take this door apart, and you’ll get to cut away the vapor barrier.  Its purpose is to prevent the windows from getting foggy from moisture inside of the door.  Tape it back on afterward if you think it’s worth the effort. 

Is this a lot of redundant pictures?  Yes.  Cause it is easy to take things apart, and tougher to put stuff back together.  This is what it looked like when it was together, and I definitely referred to these pictures while reassembling it. 

This is annoying, because we have to work through holes in the door. 

Through the big one in the lower center you can see the regulator, and through the two on the left side, see the rail.  Both of these need to be cleaned as best as you can.  After cleaning the regulator, grease it with bearing grease. 

Roll it up and down a few times to check the teeth of the gear wheel as well, shown in the triangular hole, top center.  Clean those too.  Replace them if they’re worn and you’re also a rich mofo who can afford these things. 

This’ll do for cleaning supplies.  Also a toothbrush helps, I stole my roommates’ but you can buy one or whatever. 

And then there’s nothing to do but wiggle the window up so it’s sitting on the regulator and snug within the rail on either side of the door.  I didn’t notice there were two rails until after I had already gotten the window into it, so it isn’t that tough.  Roll the window up and down a couple times to make sure it moves smoothly and it’s going to stay fixed.  Then reassemble by reversing the process, and clean the glass after everything is done. 

Multiple people told me this was going to be an annoying PITA job that would take all afternoon and tons of swearing, but it honestly wasn’t that tough.  Like an hour tops.  So good luck. 

Don’t forget to leave a callback number, so the next guy knows who to blame.