Fixing Volvo S40 Electric Window Lifter

Today I got a SMS message from my dad where he said that the driver’s window is not willing to go back up… So I needed to open the door panel at the evening and remove the lifting mechanism. And here is the problem:

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It turns out that the rubber gear inside the motor’s bevel gear had broken off from it’s vulcanization.

After a some thinking and test cutting I decided that this can be fixed by welding some metal if I’m lucky enough:

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That cut you see at the picture was totally unnecessary and I’m not recommending that you do such thing. It was a test which did not worked out. Luckily the welding held and after cutting the excess piece out:

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I also decided to put a piece of that rubber gear back and added some grease:

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Then I put the motor back together and amazingly enough it worked. I also assembled the window lift mechanism and put it back inside the door and still it worked. 😀

Let’s see how long this works but at least it is now working… Downwards the window goes like earlier, but upwards it is a bit slower. Later I will add some silicone grease to window seal to see does it help.

New lift mechanism would have cost 140€ from Motonet and the delivery time would have been long since they did not had it at stock. If this brokes down yet again then I need to order a new lift mechanism but so far so good. If I need to do this to the other door most probably the end result will be even better (or so I hope).

Some progress, some challenges

I was able to get the heater block out without breaking anything, but the new heater block was smaller than the earlier… Width of the block for this Volvo is 187mm, but the spare was only 175mm and it also was thinner. I didn’t want to use the too small heater block since it is that hard to replace if it is not working as expected.

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Now I need to return the incorrect block and order a new one… So this project is now officially delayed at least a couple of days. :-\