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Rear Window Regulator Replacement
 
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Pelican Technical Article:

Rear Window Regulator Replacement

Steve Vernon

Time:

6 hours6 hrs

Tab:

$300

Talent:

***

Tools:

Trim removal tool, T30, T27, T25, T20, T10 Torx driver, soldering iron, drill, rivet tool

Applicable Models:

Mercedes-Benz C250 (2012-14)
Mercedes-Benz C300 (2008-14)
Mercedes-Benz C350 (2008-14)

Parts Required:

Door panel with the window regulator, rivets

Hot Tip:

Melting the plastic is really tricky

Performance Gain:

Working windows

Complementary Modification:

Detail the interior

The window regulators on the Mercedes W204 are riveted to the inner door panels and cannot be bought separately. While this is getting to be more common on modern cars, it can be very frustrating when transferring over other components like speakers or locking mechanisms that are either plastic or metal riveted to the panel. On the rear door panel of the W204 you will need to drill out the speaker rivets and melt the door locking "rivets" to transfer these components to the new panel.

This article will show you how to remove your rear door panels to access the window regulator. It is not a difficult job, but door panels can be very expensive so take your time and double check things. Also, if you are going to be working on your own car, it is a good idea to purchase a set of trim removal tools. They are a set of hard yet flexible plastic tools of different shapes and sizes that are used in removing trim pieces. They work much better than a flathead screwdriver, and there is nothing worse than ruining a "do-it-yourself" project by scratching up your car or damaging expensive interior pieces. Pelican sells a full line of these tool sets for under $20.

The new window regulator comes already riveted to the door panel (red arrow) and you cannot buy the regulator separately.
Figure 1

The new window regulator comes already riveted to the door panel (red arrow) and you cannot buy the regulator separately. Unfortunately, this means transferring over all of the locking components to the new panel.

Begin by using a T30 Torx and removing the two T30 Torx bolts under the armrest (red arrows).
Figure 2

Begin by using a T30 Torx and removing the two T30 Torx bolts under the armrest (red arrows).

There are eight clips (red arrow) that hold the door panel in place.
Figure 3

There are eight clips (red arrow) that hold the door panel in place.

Some of these clips might break or stay in the door when you are removing the panel.
Figure 4

Some of these clips might break or stay in the door when you are removing the panel. You want to use the proper door panel trim removal tool and get as close to the clips as possible. Prying them out will take a surprising amount of force. You want to avoid having the plastic section of the panel that holds the clips break. Also, do not pull on the panel with your hands, as you risk bending or damaging the panel itself.

Lift the door panel up and out of the window channel starting at the rear and working your way forward.
Figure 5

Lift the door panel up and out of the window channel starting at the rear and working your way forward. With the panel off, reach in and squeeze the two clips on the Bowden cable together and release the cable from the mount, and slide it out of the opening in the panel (yellow arrow).

Remove the door pull cable from the panel by pulling it back and slipping it out from the cable mount (red arrow), and then lifting it up out of the handle (yellow arrow).
Figure 6

Remove the door pull cable from the panel by pulling it back and slipping it out from the cable mount (red arrow), and then lifting it up out of the handle (yellow arrow).

Unplug the electrical connections from the control unit (red arrow).
Figure 7

Unplug the electrical connections from the control unit (red arrow).

Disconnect the electrical connection from the window motor (yellow arrow).
Figure 8

Disconnect the electrical connection from the window motor (yellow arrow). Use a T25 Torx to remove the three Torx screws (red arrows).

Pull the motor out from the door panel.
Figure 9

Pull the motor out from the door panel. The motor gear (red arrow) fits within the plastic geared spindle in the regulator (yellow arrow), which drives the window up or down.

Remove the large plug in the door that covers the window attachment point (red arrow).
Figure 10

Remove the large plug in the door that covers the window attachment point (red arrow). With the motor removed you can slide the window up or down with your hands until you have access to the T27 screw that holds the window to the regulator. Remove the screw and then pull the window all the way to the top, and tape it securely in place.

This photo shows the T27 Torx screw that clamps the window to the regulator (red arrow).
Figure 11

This photo shows the T27 Torx screw that clamps the window to the regulator (red arrow). Make sure you do not strip this screw when removing it, or you will be in for a heck of a time getting the window separated from the regulator.

Close the rear door and open the front.
Figure 12

Close the rear door and open the front. You are going to separate the wiring harness by pressing down on the tab on the harness and then lifting the plastic hinge (red arrow).

With the harness removed from the chassis push the grommet and harness into the body of the door (red arrow).
Figure 13

With the harness removed from the chassis push the grommet and harness into the body of the door (red arrow).

Open the rear door and remove the grommet on the doorframe (red arrow).
Figure 14

Open the rear door and remove the grommet on the doorframe (red arrow). Pull the wiring harness out.

Use a T30 Torx and remove the three Torx screws holding the latch/lock in place (red arrows).
Figure 15

Use a T30 Torx and remove the three Torx screws holding the latch/lock in place (red arrows).

You will need to remove the door handles, so please see our article on door handle removal for additional assistance.
Figure 16

You will need to remove the door handles, so please see our article on door handle removal for additional assistance. With the door handles removed remove the two gaskets and loosen the T20 screws underneath (red arrows). Using hand pressure on the screws slide the backing plate towards the front of the door.

You now need to drill out all of the stainless steel rivets along the outer section of the panel (red arrows).
Figure 17

You now need to drill out all of the stainless steel rivets along the outer section of the panel (red arrows). Do not drill out any rivets on the inside section of the panel (yellow arrow).

Remove the panel from the doorframe and transfer all of the components over to the new panel.
Figure 18

Remove the panel from the doorframe and transfer all of the components over to the new panel. You can see here how the window sits in the regulator (red arrow). Use care, as you will need to melt the plastic rivets for the locking mechanism but leave enough on the rivets that you can reattach it to the new panel (green arrows). Make sure to pass the cables and electrical wires through and install the grommets in the opening (yellow arrows) before re-melting in the rivet. Installation is the reverse of removal.

Check the panel before reinstalling it to make sure all the clips are in the panel and not the door.
Figure 19

Check the panel before reinstalling it to make sure all the clips are in the panel and not the door. This photo shows the location of the clips.

If a clip remains in the door simply remove it and reinstall it along with the rubber isolator (red arrow) back into the mount in the panel (yellow arrow).
Figure 20

If a clip remains in the door simply remove it and reinstall it along with the rubber isolator (red arrow) back into the mount in the panel (yellow arrow). Installation is the reverse of removal.

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Page last updated: Wed 12/7/2016 02:58:19 AM