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Replacing Your Audi A4 Rear Door Component Carrier
 
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Pelican Technical Article:

Replacing Your Audi A4 Rear Door Component Carrier

Steve Vernon

Time:

4 hours4 hrs

Tab:

$0

Talent:

***

Tools:

T45, T30, T27, T25 Torx driver, 8mm 12 point, Philips & Flathead screwdriver, needle nose pliers, trim removal tool

Applicable Models:

Audi A4 (2002-05)
Audi A4 Cabriolet (2003-06)

Hot Tip:

Try everything before you reinstall the door panel

Performance Gain:

Access to the door systems

Complementary Modification:

Really clean the glass

The rear door component carrier does exactly what its name describes. It carries the window regulator, glass, braces for the door and locks and must be removed to work on these systems. This article will show you how to remove the carrier and all its components from the door.

To begin, you will need to remove the door panel. Please see our article on removing your rear door panel and complete the work there before starting this project.

This photo illustrates the door with the door panel off.
Figure 1

This photo illustrates the door with the door panel off. You are going to start with removing the speaker (red arrow), the regulator motor and then the weather protective shield (green arrow).

Begin by squeezing in the two tabs on the speaker connection (red arrows) and pulling it out from the speaker.
Figure 2

Begin by squeezing in the two tabs on the speaker connection (red arrows) and pulling it out from the speaker.

Using a Philips head screwdriver remove the three screws (red arrows, two shown) and then the speaker from the door.
Figure 3

Using a Philips head screwdriver remove the three screws (red arrows, two shown) and then the speaker from the door.

Next, you will want to remove the window regulator motor.
Figure 4

Next, you will want to remove the window regulator motor. Use a T25 Torx and remove the three screws (red arrows) holding it to the regulator.

Disconnect the wiring connections (red arrow) from the motor and remove it from the door.
Figure 5

Disconnect the wiring connections (red arrow) from the motor and remove it from the door. The connections can only fit one way into the motor, so you do not need to worry about labeling them.

Clip the small zip tie holding the wiring to the doorframe (red arrow).
Figure 6

Clip the small zip tie holding the wiring to the doorframe (red arrow).

Carefully peel back the weather proof membrane (red arrow).
Figure 7

Carefully peel back the weather proof membrane (red arrow). It is glued to the door. If you use a razor blade and take your time, you can remove it without damaging it and reuse it on reassembly.

If you bought the car used, sometimes repairs like this have already been performed and sometimes not everything is put back or done properly.
Figure 8

If you bought the car used, sometimes repairs like this have already been performed and sometimes not everything is put back or done properly. This was the case with our project car. There should be a protective plate up towards the top center of the panel by the green part of the regulator. This is held in place with two screws (red arrows). If you still have this panel, remove it now. Next, you need to free the regulator mechanism from the doorframe (yellow arrow).

Use a set of needle nose pliers or a small flathead screwdriver and squeeze in the three posts (red arrows) and push the mechanism into the doorframe.
Figure 9

Use a set of needle nose pliers or a small flathead screwdriver and squeeze in the three posts (red arrows) and push the mechanism into the doorframe.

Here is another example of components not replaced by the previous owner.
Figure 10

Here is another example of components not replaced by the previous owner. There is a foam insert that goes along the end of the doorframe and under the red arrow. If you have this piece, you can just remove it. You now need to peel back the weather stripping from the upper section of the door frame; it easily just pulls out from the channel. At some point in the past someone just cut the door seal (yellow arrow), so they would not need to remove it; we do not recommend this method.

Pull the end of the weather protective flap from the two retaining holes in the door (red arrow).
Figure 11

Pull the end of the weather protective flap from the two retaining holes in the door (red arrow).

Remove the rubber cap.
Figure 12

Remove the rubber cap. Using a T45 Torx, remove the large Torx screw (red arrow); next, remove the other T45 Torx (yellow arrow).

Remove the single T30 Torx screw below the lock (red arrow).
Figure 13

Remove the single T30 Torx screw below the lock (red arrow).

The front of the door was the same as the rear.
Figure 14

The front of the door was the same as the rear. There is a foam insert that goes along the end of the doorframe and under the red arrow. If you have this piece, you can just remove it. You now need to peel back the weather stripping from the upper section of the door frame; it easily just pulls out from the channel. At some point in the past, someone just cut the door seal (yellow arrow) so they would not need to remove it; we do not recommend this method.

Remove the rubber cap.
Figure 15

Remove the rubber cap. Using a T45 Torx, remove the large Torx screw (red arrow); next, remove the other T45 and T30 Torx screws (yellow arrows).

Pull the end of the weather protective flap from the two retaining holes in the door (red arrow).
Figure 16

Pull the end of the weather protective flap from the two retaining holes in the door (red arrow).

Use a T25 Torx and remove the single screw holding the bottom of the regulator to the doorframe (red arrow).
Figure 17

Use a T25 Torx and remove the single screw holding the bottom of the regulator to the doorframe (red arrow).

Gently pull the rear door component carrier, glass and window regulator up and out from the door and lay it on a safe flat surface.
Figure 18

Gently pull the rear door component carrier, glass and window regulator up and out from the door and lay it on a safe flat surface.

If you need to remove the window regulator and glass from the component carrier, use a T25 Torx and remove the two screws that hold the glass in place on the regulator (red arrows).
Figure 19

If you need to remove the window regulator and glass from the component carrier, use a T25 Torx and remove the two screws that hold the glass in place on the regulator (red arrows).

Carefully lift the clip on the bottom of the glass over the regulator and slide the glass down and out from the frame (red arrows) Place the glass in a safe area.
Figure 20

Carefully lift the clip on the bottom of the glass over the regulator and slide the glass down and out from the frame (red arrows) Place the glass in a safe area.

You can now remove the single T25 screws holding the regulator to the window frame (red arrow).
Figure 21

You can now remove the single T25 screws holding the regulator to the window frame (red arrow).

You now have a complete and bare door component carrier.
Figure 22

You now have a complete and bare door component carrier. Installation is the reverse of removal.

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