How to Replace Window Regulator Sash Connectors 1997-2003 Chevy Malibu
Created on: 2011-09-27
How to install, fix, change or replace broken or snapped window sash connectorson 1997-2003 Chevy Malibu models.
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step 1 :Disconnecting the Battery
- Disconnect the Negative battery cable with am 8mm wrench
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step 2 :Removing the Door Panel
- Pry off the trim behind the door pull with a flat blade screwdriver
- Pry off the window switch panel with a flat blade screwdriver
- Disconnect the window switch wiring harness
- Pry off the mirror base bezel with a flat blade screwdriver
- Remove the Phillips head screw from inside the door handle
- Remove the two 7mm bolts from behind the door pull
- Pry off the door handle bezel with a flat blade screwdriver
- Disconnect the door lock wiring harness from the door handle bezel
- Pry the door panel off by hand
- Carefully peel back the water shield
- For more detailed instructions, please see the 2001 Malibu door panel replacement video
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step 3 :Removing the Window
- Remove the two 10mm nuts from the window sash connectors
- Lift the window by hand
- Connect the negative battery cable
- Connect the power window switch
- Lower the regulator with the switch
- Pull off the window weatherstrip
- Lower the window slightly
- Tilt the window forward
- Lift out the window
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step 4 :Removing the Window Sash
- Pop out the middle of the sash rivet with a punch and hammer
- Drill out the rivet with a 1/4" drill bit
- Hold the rivet with pliers if necessary
- Pull out the rivet with pliers
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step 5 :Installing the Window Sash
- Put the window sash onto the window
- Use a rivet gun to put a rivet into the window sash
- If you do not have a rivet gun, put a bolt and locking nut through the sash
- Tighten the nut onto the sash
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step 6 :Installing the Window
- Tilt the window forward
- Lower the window into the door
- Straighten out the window
- Lift the window up by hand
- Raise the window regulator with the window switch
- Lower the window sashes onto the regulator
- Fasten the two 10mm nuts onto the window sashes
- Test the window with the switch
- Push on the window weatherstrip
- Disconnect the window switch wiring harnesses
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step 7 :Reinstalling the Door Panel
- Put the water shield back on, pulling through all the wiring harnesses
- Put the door panel into place, pulling through all the wiring harnesses
- Reconnect the window switch wiring harnesses
- Push the window switch panel into place
- Connect the door lock wiring harness to the door handle bezel
- Push the door handle bezel into place
- Insert the Phillips head screw into the door handle
- Insert the two 7mm bolts behind the door pull
- Push in the trim piece behind the door pull
- For more detailed instructions, please see the 2001 Malibu door panel replacement video
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step 8 :Reconnecting the Battery
- Connect the negative battery cable using an 8mm wrench if you have not already done so
Tools needed
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Socket Extensions
Hammer
8mm Wrench
Rivet Gun & Rivets
Flat Blade Screwdriver
Phillips Head Screwdriver
1/4 Inch Drill Bit
Center Punch
7mm Socket
Drill
10mm Socket
Ratchet
Needle nose pliers
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Hi, I'm Mike Green. I'm one of the owners of 1A Auto. I want to help you save time and money repairing or maintaining your vehicle. I'm going to use my 20-plus years experience restoring and repairing cars and trucks like this to show you the correct way to install parts from 1AAuto.com. The right parts installed correctly: that's going to save you time and money. Thank you and enjoy the video.
In this video, we're going to replace the window sash connectors on this 2001 Chevy Malibu. These are the little plastic connectors that connect the regulator to the window. When they break, your window can then go up and down by itself without the motor. Tools you'll need are a flat blade screwdriver, Phillips screwdriver, 7mm and 10mm sockets with a ratchet and extension, pliers, and a drill and a 1/4" drill bit.
With an 8mm wrench, disconnect your negative battery cable. This is really just to protect your battery from running down. I do reconnect it a couple times during the video to test things out.
We're going to fast forward through removing the door panel. If you want to see this in regular speed, you can just check out our other videos. There's probably enough here to figure it out. Remove the switch, unplug it, remove the bezel around the door handle and a couple other bezels, and pull the door panel off. You'll want to remove your water shield, just pull it down enough so you can see everything.
Right here are your sash connectors. Oftentimes these can break. You can see on my car they're actually fine, but I'm going to take them apart and change them just to show you how to do it. You want to actually remove these two 10mm nuts. Use a 10mm socket with a ratchet and extension. You can actually just loosen those two nuts. Next you want to just pull the window up and I'll actually reconnect my switch here. Turn the key on. Run my regulator down some. Now I'm going to take the window out. I'm going to take this weatherstrip here that's on the inside, pull it up and off, and run my window down. I'm going to push the front down, pull the back up, and pull it right out.
The old sashes are held on by a rivet. What you want to do is you want to pop the middle of the rivet out. Take a punch, hold it down on there, and obviously you don't want to smash the window, but you don't have to worry too much about breaking this because it's safety glass. Now the middle of the rivet's gone. Use a 1/4" drill bit. If the rivet should start spinning, you can hold onto a piece of it with pliers on the back side. Here I'm using my pliers to pull the rest of the rivet out.
Take your new sash connector and put it in. If you have a rivet gun, then you can put it back with a rivet, that's the best thing. If not, I'm using an M5 . it's an M5 2cm long bolt. Feed it up from the outside of the window. Then I'm using a nut that has the nylon lock on it. Here I'm going to tighten up that nut. You want to have it nice and firm, but don't over tighten them, and then obviously repeat for the other connector if need be.
I'm ready to put my window back in. You can see that the bolts, the ends that protrude are facing the inside of the vehicle. Put the window down in. First make sure you pull your outside weather strip out a little bit. Now get your window into your rear channel here. Here's a closeup looking down the back of the window. You can see the bottom of the window, you want to make sure it's in between the rubber and it's right in the channel.
As the front comes up, make sure it's in the middle of that channel, and slide the window back. You can bring it up some if you want. Turn my key on. Turn my window regulator up some so I can see the bolts. Then I'll bring my window down. Get my connectors to meet like they should. You can see there's that connector. That connector's all set. Tighten those up nice and firm.
Turn the key back on. Everything works together quite nicely. Put this weather strip back on, slide it here in the front. Slide it forward and down. Take off our switch. Like in the beginning, we're going to fast forward through putting the door panel on. Make sure you pull those harnesses through, and then everything kind of goes back in reverse order. Then, in addition to this, just make sure you reconnect your negative battery cable, and you'll be all set to go. If you want to see replacing this door panel in regular speed, just check out our other videos.
We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.
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