Side Window Ribbon Replacement

by Scott Fabre

 

Last Update: 08/03/2005

 

 

The symptom was that the window would not go up all the way. This was caused by a break in what is called

the "ribbon". The ribbon can be purchased from Mid-America or Ecklers or GM or many other sources.

 

DISCLAIMER. What you are about to do may not be described in the GM manual. In fact I know it isn't. They

say to "remove and repair" the window. If you attempt any of this it is at your own risk.

 

Also, the pictures have a date and time stamp on them. Ignore the chronological order of time because I have

just arranged the pictures in what I feel is the most useful order.

 

For the record, the car I am working on here is not my ZR1. It is my brother's C4 (narrow car). The window drive

mechanism is the same as is in out ZR1. Now for some fun pictures and comments on this latest installment of

"How to".....

 

First remove all obvious screws holding the

door panel in. There are about six around the

bottom (his 85 had the bose speaker grill to

be removed) A tricky one is on the back of the

door near the clasp. Another tricky area is in

the door handle area (inside door handle). There

are two philips head screw in there that are not

difficult to remove but can be a pain in the butt to

put back in.

 

 

There is a bit of detail left out above

sorry. It requires you to disconnect

all the electrical connectors. Some

are a royal pain. Be careful to study

each one as to where and how the

retainer works so you don't break one.

 

Remove the plastic barrier.

 

Disconnect the remaining connectors.

 

There are about 10 hex head sheet

metal screw holding in the aluminum

sheet metal piece.

 

Here is the last of the sheet metal screws, don't

drop the little suckers in the door panel!

 

There are two bolts holding a bracket (above).

DON'T drop the bracket once the bolts come off.

 

Next are the actuator rods. There are two of them.

This was the tricky one in that there is no need to

disconnect the end at the left side that connects to

the door latch. Just pry the two tangs shown above

apart so that the rod can be separated from the

aluminum sheet panel. There is also a white plastic

piece that the rods run through behind the aluminum

just pop the rods out of the plastic. There just a

pressure fitting.

 

Now for the little white rod end retainer.

 

This comes off by pushing back and to the left on

just the plastic piece.

 

Now you should be able to pull out the

sheet metal piece to expose the rod end

clasp for the inside door release latch.

Remove the retaining clip by inserting a

small flat blade screw driver under the

clip then work it away from the rod and

toward the inside of the door.

 

Swing the sheet metal out of the way.

(see it just above my right hand?)

 

Remove the two bolts in this area and the

one to the right but make sure someone is

holding onto the window glass!

 

This picture and the next few are technically

out of order. The were actually taken while

putting the fixed unit back in but hey, same

deal as taking it out. To remove this piece

take off the two nuts holding the top and the

two on the bottom of the door. NOTE: the two

on the bottom of the door can be felt by running

your hand along the bottom of the door. They

are 10mm (I think, sorry this was yesterday...

already out of my short term memory)

 

After all the fasteners are out, rotate left,

pull the top out and then lift up and pull

out the bottom.

 

Here I am pulling out the bottom.

 

Now let's get it up on the bench to take a look.

 

Just a full view of the unit.

 

Ah, here is the break....

 

Drill out the 5/32 in rivets on the top.

 

Remove the allen head screw.

To remove the broken ribbon pieces

apply 12v to the motor.

 

Now the first of two ribbon pieces can be

removed. DON'T FORGET to remove the

small broken off piece. Use the motor with

12V again to get the little piece off.

 

Ah, here is the extracted broken ribbon.

 

Here is where you can try to install the new

ribbon but wait. It won't fit. I wonder why?

 

Hmmm, seems to be a bit longer than

the two old pieces put end to end. You

will need to cut the new one to the same

length as the two old broken pieces.

 

Ok, all better now. New ribbon piece is in and

the allen head screw is in place. (NOTE: the

round shaft will look bent in more than one place

almost as if it were in an accident then rebent back.

This wavy bend is normal. Do not try to make the

bend a single curve)

 

Now a word of warning. The two replacement

pop rivets sent with the kit are the wrong size.

Pitch these because they are too big. (3/16 in)

Use 5/32 in pop rivets.

 

When reassembling use loctite on all critical

window mechanisms. You don't want to have

to get back in there for a loose screw/nut. I

used the blue loctite. ( I don't know what the

number is and don't care) Virtually any paint

will work here too. That's all loctite is.

 

Now for a little mineral oil on the ribbon to

metal contact area.

 

Oh, yeah when putting the aluminum sheet

metal piece back in don't forget to put in in

FRONT of this captive nut flange. It is a real

pisser if you forget. (note picture show how

to do it WRONG!)

 

This picture is for Milstead. It can be used

for multiple things, everything from door

windows to feeling regular again.

 

And then it was all back together again like magic.

 

 

 

  Disclaimer:  Repairs and techniques are reported here by amateurs and professionals as an informational opinion service only and should not be attempted by other than factory trained and certified technicians. The ZR1 Net does not recommend anyone doing these procedures and is not responsible for any adverse outcome. Factory repair manuals should always be used and followed to the letter in conjunction with any repair or maintenance performed. All cautions and warnings that appear in the factory manuals apply here as well. As recommended in all service manuals, proper eye and body protection as well as proper tools must be used for any maintenance performed by individuals. Working on automobiles is dangerous and could result in personal and/or property injury. If you do not have the proper tools or know-how, you should not do any of these procedures, but have a qualified technician perform the work.  
   

horizontal rule

 

ZR-1 Net Registry
zr1net@zr1.net


Copyright © 2002 ZR-1 Net Registry