I started that project this morning, the black piece is not broken, and I bought the wrong size corner bracket. The techinfo article said 1.5", that is not right, it only leaves 1/2" in the middle. THe biggest problem I am having is winding the wire back onto the spool, it is all kinked up. Once I get it on to the reel, it is IMPOSSIBLE to get it back on to the post. any ideas or experience in this?

My wire was kinked pretty bad aswell take a piece of leather or a rag, wrap around the cable and CAREFULLY squeez out the kinks with a pair of pliers. Once you have the cable around the pully you want to use a screwdriver to pry it into position. you will want to put the black cover over the pulley as soon as your in position so put it on the srewdriver with the pulley pry it into position and snap the cover on. the screwdriver might bend some teeth on the pulley so you may have to clean them up afterwards. good luck and be patient you'll get there, also be sure to get the cable as tight around the pulley as possible before it will make it way easier to get the pully where it goes.

Hey, thanks a lot. I was working the screwdriver technique, but the teeth seemed so soft, and I was still like 1/8" off. Hopefully that advice about taking out the kinks will give me the extra space I need. Again, thanks!

There is alot of knowledge about this here just ask if yo have any other hang-ups. Oh and welcome to the club.

EDIT: this may help you dunno.
http://www.bonnevilleclub.com/forum/...968&highlight=

I agree with Cruiser. I had to fix both my rears and one was a breeze and the other was rough. My cable was kinked also, I wrapped it as tightly as I could and used the screwdriver to pry it on. One bit of advice I can give is...after you get the cover on hold pressure on it while you bend the little posts back into place. Bend them down tight and all should be well.

Tim

It is a 1.5 inch corner bracket, which means each side is 1.5 inches for a total of 3 inches. As they said above, try to straighten the cable as much a you can. The more times someone tried to activate the window after it broke, the more tangled the cable will be. Try to keep the cable in the grooves of the reel also. I used a large phillips head screwdriver to align the reel. That allowed most of the pressure to be on the center of the spool, keeping it away from the teeth of the gear.

Apparently I was putting so much force on it, I broke the big white piece, just the end of it, where the cable is held in. Since I had a corner bracket that was too small, I wedged that in there with a very small locking washer to keep the cable from slipping through the corner bracket on the one end, and wedged the other piece into the gap behind the spring that the black piece use to cover. I should've took a picture, but the way that it'* in there, I doubt I'll ever be taking it back out. The good news is, it works like new. And many thanks to all of the contributors to the site! You guys have saved me a ton of money over the last 2 years.

If I'm understanding what you did properly, that will work. The idea is to support both cables with the bracket, and you've done that. Good job!

boy that sounds awful... I'm next doing the fix... I haven't takent it out yet so I don't know how kinked it is... and i've accidentally hit that button a time or two in the weeks since I dissembled it... oy I

I finally disassembled the whole thing, and as I suspected, the wire is very kinked, plus it came apart where the two ends are joined to each other, and is no longer a continuous piece of wire. The wire connected to the top part is in good shape, but the bottom part is kinked and frayed.

I was thinking that I need to get a new wire for the bottom, but will I be able to connect it to what is the pieces already there? If not, how do I reconnect the two ends? Any ideas?