Power window fix

Mitsubishi Delica L400 production commenced in 1994 -- After much anticipation, the L400 arrived on Canadian Soil in 2009!
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Feds
Posts: 314
Joined: Fri Jan 07, 2011 11:16 am
Member's Photo Album: http://www.delica.ca/Photos/
Vehicle: 1996 Royal Exceed (in transit)
Location: Sunny Fenwick

Power window fix

Post by Feds »

Since I bought my Delica, the passenger side window motor would spin, but the window would not go up or down without help. Clearly something was stripped. Last night, I got after the fix.

The door panel comes off with 3 or 4 screws, and to get the regulator out, I used this tutorial:

http://www.delicaclub.com/viewtopic.php?p=169885#169885

After that, the motor comes off from the regulator with 3 screws, and the cap can be pried off with a screwdriver, leaving you with this:

Image

Some investigation showed that the rubber had separated from the smaller gear that actuates the window mechanism. The red line points to the separated area. It's not necessarily a bad design, but it definitely failed at the weakest point.

To fix, I ground a slot through the rubber and the small gear, and I cut a chamfer in the rubber around the small gear using an exacto knife:

Image

To transfer the torque better, I put a piece of tubing into the slot (brake line tubing that I had in the garage, you could use a bolt, a nail, whatever you have kicking around).

Image

Then JB-welded the whole thing:

Image

My theory is that the JB weld only needs to hold the tube to the back of the gear. The tube itself should transfer the torque from the rubber to the gear. Any torque transfer that occurs via the JB weld in the chamfer is just bonus. Looking back on it, I probably should have just tack-welded the tube onto the back of the gear. That'll be plan B if this fails.
DeliTan2
Posts: 37
Joined: Tue Jan 15, 2019 9:26 am
Member's Photo Album: http://www.delica.ca/Photos/
Vehicle: L400 Series 1 LWB
Location: south interior of BC

Re: Power window fix

Post by DeliTan2 »

Hi Folks;

After a hot summer without the capability to operate the driver's window, I needed a fix. Maybe I'll fix the AC one day...

I have the exact same problem as the OP but wanted to find another solution that retains the cushioning effect (in case it's important). I have tried to get a used motor but failed. I'm not confident a used one will work (for long) and a new one is over $600.

So, I took the motor drive mechanism apart by machining down the shaft that goes through the housing and has the steel gear attached. Once apart, I drilled and tapped the shaft that I had machined down so I could reassemble it later.

Next time I'm in Vancouver I'll get some casting rubber and pour a new doughnut between the 2 round steel bits.

Lots of time; not much money. Hope it works...

john
DeliTan2
Posts: 37
Joined: Tue Jan 15, 2019 9:26 am
Member's Photo Album: http://www.delica.ca/Photos/
Vehicle: L400 Series 1 LWB
Location: south interior of BC

Re: Power window fix

Post by DeliTan2 »

Returned from Vancouver last night with some casting urethane. Same brand as deskinthewoods used here: ReCasting Bushings with Polyurethane but a different product. I had no idea Crappy Tire carried the product.
Today I cut out the old rubber with various blades and surprisingly didn't cut myself; even once!

Using a Dremel and a belt sander I cleaned up the surfaces and wiped with acetone. I built a jig to hold the parts coaxially while the compound cures. Tonight I mix and pour, and tomorrow afternoon, we'll see...

john
DeliTan2
Posts: 37
Joined: Tue Jan 15, 2019 9:26 am
Member's Photo Album: http://www.delica.ca/Photos/
Vehicle: L400 Series 1 LWB
Location: south interior of BC

Re: Power window fix

Post by DeliTan2 »

I couldn't get on this site to post an update for a while, but here's where I am now;
After the casting had cured, I put it all together and assembled the door.
YSW7vVfBTWSRzV94VkL4xw_thumb_732c.jpg
YSW7vVfBTWSRzV94VkL4xw_thumb_732c.jpg (86.44 KiB) Viewed 777 times
At each stage I tested the window and it worked fine until I finished the door trim. Then it failed. Took it all apart again and found the urethane had cleanly separated from the inner hub.
tTqe+RsqSgmY18N%yptN9g_thumb_732f.jpg
tTqe+RsqSgmY18N%yptN9g_thumb_732f.jpg (85.64 KiB) Viewed 777 times
After some thought, I welded 4 "wings" on to the inner hub to give it more surface area to stick to, and even if it doesn't stick, it will mechanically transfer the rotation (I hope). Recast the urethane, cured, reassembled the mechanics but left the door trim off until it's tested for a while.
K4eFLvZZR3SbFFEMyi1jcg_thumb_7331.jpg
K4eFLvZZR3SbFFEMyi1jcg_thumb_7331.jpg (83.03 KiB) Viewed 777 times
gauGcKodQQ+3PwEQ+MVafg_thumb_7339.jpg
gauGcKodQQ+3PwEQ+MVafg_thumb_7339.jpg (69.62 KiB) Viewed 777 times
Once I get my brakes fixed (stuck caliper again), I'll "spring clean" the van and test the window extensively before putting the door trim back on.

I will post in this thread again if the problem re arises, otherwise, it's still working or I no longer own the van...

john
DeliTan2
Posts: 37
Joined: Tue Jan 15, 2019 9:26 am
Member's Photo Album: http://www.delica.ca/Photos/
Vehicle: L400 Series 1 LWB
Location: south interior of BC

Re: Power window fix

Post by DeliTan2 »

Still working fine...


john
thelazygreenfox
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Vehicle: 99 white Hi roof gas Chamonix
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Location: coquitlam canada

Re: Power window fix

Post by thelazygreenfox »

If your windows need help up or down try lubing the front and back door tracks the window slides in. Usually the windows stick in the rainy season but a little grease in the tracks is all they need. No door surgery needed. All three of my delicas have needed this fix.
MD :-D
Wear your mask, it keeps others from seeing the parsley in your teeth
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