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Volkswagen New Beetle: 1998 and later Window regulator kit installation problem


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Last Post: Dec 19, 2013 7:29 PM Last Post By: ls1
BeetleDad

Posts: 207
Registered: 08/22/08
Window regulator kit installation problem
Posted: Oct 3, 2008 4:21 AM
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I am installing the window regulator repair kit on our 1999 New Beetle and can't get the cable over the last pulley since there is so much tension on the cable. The Technical Bulletin (see pdf kindly provided by FKH161) shows that you need Special Tool JC4100 to install the cable over the pulley. Does anyone know how I can do this without the tool or where I can buy the tool? I'm at a dead-end. Help!

I am also attaching a pdf for SE Tools that makes this tool. You will have to scroll all the way to the bottom of catalog to see it. I'm going to call them to see about the cost of the tool, but I bet it is expensive. I'll post that after I find out.
BeetleDad

Posts: 207
Registered: 08/22/08
Re: Window regulator kit installation problem
Posted: Oct 6, 2008 11:32 AM   in response to: BeetleDad in response to: BeetleDad
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We solved the problem by making our own tool. I am enclosing pictures of the tool we made in case anyone needs to do the same thing. We took a metal shelf bracket and made this. It made turning the pulley to get the cable on a snap. Window works again!
74transporter

Posts: 17
Registered: 01/16/08
Re: Window regulator kit installation problem
Posted: Apr 27, 2009 7:47 PM   in response to: BeetleDad in response to: BeetleDad
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beautiful.

so, did you pull the the whole panel out of the door to do the install?

how can i get my hands on the regulator kit?
BeetleDad

Posts: 207
Registered: 08/22/08
Re: Window regulator kit installation problem
Posted: May 9, 2009 4:58 PM   in response to: 74transporter in response to: 74transporter
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Yes, we pulled the whole panel out of the door. We bought the regulator kit at our local VW dealer for about $65.00. It wasn't much more than those online and I could return it if I had to.

Side note: if you still can't get the cable over the pulley, you might ask your dealer if they would slip it over it for you if you bring the panel in. Ours was going to do that for me for about $50. That's when we made our own tool.
Bresha

Posts: 433
Registered: 02/23/09
Re: Window regulator kit installation problem
Posted: May 10, 2009 1:00 AM   in response to: BeetleDad in response to: BeetleDad
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Hi BeetleDad,
No tool needed for installing window regulator kit, next time when you have one, do not use tool, just look at the pulley setup, and I'm sure you going to figure it out.

Bresha
74transporter

Posts: 17
Registered: 01/16/08
Re: Window regulator kit installation problem
Posted: Jun 10, 2009 2:03 PM   in response to: BeetleDad in response to: BeetleDad
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Attachment IMG_1835.JPG (146.1 KB)
Attachment IMG_1836.JPG (141.2 KB)
Attachment IMG_1837.JPG (195.9 KB)
hey guys,

what was in your kits? this is all i got.
Bresha

Posts: 433
Registered: 02/23/09
Re: Window regulator kit installation problem
Posted: Jun 10, 2009 11:36 PM   in response to: 74transporter in response to: 74transporter
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You got everything you need to proceed, good luck.

Bresha
scottbjer

Posts: 1
Registered: 06/12/09
Installing new window regulator in New Beetle
Posted: Jun 12, 2009 10:53 PM   in response to: Bresha in response to: Bresha
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Attachment IMG_0182.JPG (319.3 KB)
Hey -

Just thought I'd reply and say thanks for all the help. I was able to replace the window regulator today and figured I'd share some key things (in addition to documentation above).

How to remove inner door panel:
==================================
See http://www.newbeetle.org/forums/questions-issues-concerns-problems-new-beetle/35527-how-door-panel-window-regulator-door-latch-removal.html

Where to buy replacement regulator and part number (2000 beetle)
===============================================
http://www.partsgeek.com/catalog/2000/volkswagen/beetle/body_mechanical_-ar-_trim/window_regulator_kit.html

"Special tool" for wire
========================
The "special tool" that you need to pull wire over final pully, I actually made mine out of a piece of wood and two nails, worked perfect! Might be a bit easier for a novice to make compared to metal one above. See attached picture

"Triple square" bits (for removing inner door panel)
==============================
For some reason couldn't find these anywhere local, so ordered a real nice set from here (VIMXZN100)

http://www.amazon.com/gp/product/B000I1Q60O/ref=ox_ya_oh_product

Hopefully this helps out others, since doing this fix yourself will only cost you about $75 max

Scott

74transporter

Posts: 17
Registered: 01/16/08
Re: Installing new window regulator in New Beetle
Posted: Jun 15, 2009 5:51 PM   in response to: scottbjer in response to: scottbjer
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installed and working.
thanks.

trick for getting the cable around the last pulley:

don't seat that cable guide end when the directions tell you to.
after everything else is in place, loop the cable around the pulley and then stretch and pull to seat the cable guide end.
Bresha

Posts: 433
Registered: 02/23/09
Re: Installing new window regulator in New Beetle
Posted: Jun 15, 2009 9:44 PM   in response to: 74transporter in response to: 74transporter
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There we go, figured it out, that it is what i was talking about, congratulation.

Bresha
singingsue

Posts: 2
Registered: 07/10/09
Re: Installing new window regulator in New Beetle
Posted: Jul 10, 2009 1:26 AM   in response to: Bresha in response to: Bresha
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Please help! I bought a right window regulator kit for my 200 VW Beetle and it didn't come with any instructions. We can't even get started. I went to my mechanic who tells me that it'll cost us $200-$300 minimum for him to "Fit the jigsaw puzzle together". I'd rather not do that if we can find out how to do this. We had trouble following the Technical Bulletin attached to an earlier post on this blog. Does anyone have clear directions?
Bresha

Posts: 433
Registered: 02/23/09
Re: Installing new window regulator in New Beetle
Posted: Jul 10, 2009 1:41 AM   in response to: singingsue in response to: singingsue
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Singingsue, have you not check all replays to related issue, just go back an read, all info are there!!!thanks to those guys they posted it.

Bresha

VWSPE92

Posts: 1
Registered: 07/22/11
Re: Installing new window regulator in New Beetle
Posted: Jul 22, 2011 1:34 PM   in response to: scottbjer in response to: scottbjer
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I have purchased the regulator kit and almost installed it. I have the new black plastic "cable box" screwed in place. However I still have trouble getting that last cable over the pully. I looked at the two pictures posted and see how to make the tool. I am not sure how you used it to help out though. Can you go into more detail about how you managed to take care of that last corner? thanks
BeetleDad

Posts: 207
Registered: 08/22/08
Re: Installing new window regulator in New Beetle
Posted: Jul 22, 2011 2:15 PM   in response to: VWSPE92 in response to: VWSPE92
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Place the two "nubs" on the metal tool (or the nail heads on the wooden tool) into the slots on the top of the pulley. Simply rotate the pulley with the tool and the cable should seat itself.
ls1

Posts: 1
Registered: 12/19/13
Re: Installing new window regulator in New Beetle
Posted: Dec 19, 2013 7:29 PM   in response to: scottbjer in response to: scottbjer
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well guys, made the tool, used a 6 foot cheater bar and still can't get the cable on. Tried the loop over the pulley and tug on retainer and is at least 3/4 " away from slots.Tried prying on retainer and still no go. Has anyone found the cable to be just too darn short? I can't imagine they meant for the cable to be that tight. The 1/4 window cable was tight...but no where near this tight.

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