Update:
I finally fixed the wire pulley housing also. Heres a description -
- Keep the glass as high up as it can go and hold it there by some means - I used a high grip modelling clasp such that there was about an inch of the window left open and giving me some play in the wire.
- remove 4 nuts and 1 screw holding the motor assembly in place. Do not move the motor more than a few inches away from the door or the wire wind will have wrong play while putting everything back. Use smaller tools to get to the small screws capping the pulley
- remove the couple of screws holding the metal cap in place - this is where my wires had become trapped.
- remove the plastic tubing feeders with a spring around them from the housing. I also put a tape around these tubes as the wires kept slipping out thru the groove running down their center.
- push up and remove the round pulley assembly completey and untangle the wires. My wires had also frayed a bit.
- Figure out and mark the direction of the rotation when you press the window button up/down - basically its anticlockwise if you're looking at it from the inner assembly side
- Now wind the wires back on the pulley by hand - the wire coming from the top goes on the top hole of the pulley. When you insert the wire head, follow the direction of the groove next to that hole and wind the wire around as tight as you can by hand.
- similarly the wire from the bottom goes into the bottom hole of the pulley. This should be pretty tight to insert and wind maybe half a circle around the pulley -because the glass is in the up position, leaving barely any play.
- holding everything in place, insert the pulley back on the motor shaft and snap the feeder tube part back on top. I sprayed silicone around the assembly as I couldn't find my grease box - originally it had grease all over the place
- Put the metal cap back on and screw it in place. Arrange the feeder tubes on the top and bottom so that they are tight at the end where they sit in a small groove in the door.
- Make SURE that the wires go around the pulley guides on the top and bottom side on the inside of the door - they also have small guide lids that keep the wires from slipping out. Make sure the wires slip under these lids.
Bolt the motor asembly - the center part needs to be pushed in and bolted really tight to enable the door pocket screw to match its hole. Insert the electric connectors back into the door and snap the door back in place.
Thats it! :)
