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D2 - Body and Exterior Bumpers, bonnets, glass, trims - Everything outside

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  #31  
Old 10th September 2018, 08:49 AM
HPsauce HPsauce is offline
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Anything specific you'd recommend for that?
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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  #32  
Old 10th September 2018, 10:58 AM
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johnny_quattro johnny_quattro is offline
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Default Window channel lubricant

When I had the pleasure of replacing the whole rear passenger window frame (which was basically the top half of the door frame), I used a can of silicone spray from Harry Halfords. Seemed to do the trick at the time.

I'm sure the lack of lubricant plus the fact that my snapped cable was a tad rusty was the cause of the original failure. I tend to to spray all window runners/frames/guides on a 2-3 month basis, but to be honest I do it whenever I remember.
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  #33  
Old 10th September 2018, 12:24 PM
Regulus Regulus is offline
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I haven't even thought of this. It is an advice I will take to heart as well
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  #34  
Old 10th September 2018, 10:44 PM
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27litres 27litres is offline
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I use a PTFE style dry lube (spray can preferably, stick too fiddly).
Silicone spray is also good

You're after a lube that wont gather dirt.


Got a mate who uses lithium, but I think it's too grease like and attracts dirt. I use lithium on the sunroof and bonnet/boot hinges.
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  #35  
Old 25th September 2018, 04:41 PM
HPsauce HPsauce is offline
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Good progress today, no useful photos though, but a few quick notes:

Disconnected the motor easily - three Torx bolts (T10?) and a wiggle and it's off. You can then move the window up and down more easily (though not so easy with a broken pulley...)
Also need to unhook the locking button cable; unclip from it's guides and move the end round and out it pops. And peel the door seal off the outer door panel at the rear edge.

Four big bolts to free the frame; couple of shims in the lower ones - a sizeable (semi-captive) wedge at the front and a thin one at the rear.
These obviously relate to the final fit and shut lines, I didn't need the thin one with the replacement.

Lift it up to free a locating peg at the front, wiggle out the interior handle and locking cables and it's off. My shims both fell out as expected.
Note the rather tortuous route of the interior handle cable via a narrow slot, it needs care when reassembling!

There's a small piece of rubber trim blocking the front (longer) window channel that only comes off easily with the glass right up. Remove it then lower the window.
Prise off retaining clip, lift window bracket off the pin and wiggle it down until it's off. A couple of little guide pieces fall out of the channels, they go on the end of the guide pegs.

While the glass is out transfer the rear blind hooks if necessary (it was for me).

Move window to replacement frame and refit, not forgetting the little white guide pieces in the channels and to lubricate first! I found it worked best to push the window tight shut before fitting the retaining clip at the bottom. It was then a good fit when all was reassembled. And when shut refit the rubber trim at the bottom of the channel.

Fit the frame back on the door, remembering to put the handle/lock cables in the right place and keep an eye on them as you lower it down in stages.

Fit the top (shorter) bolts first and don't do up too tight. Then the lower (longer) bolts and shims as required. Test fit to the door opening and adjust by moving the bottom in and out.

Refit the motor and test. NOTE: You need to connect the rear door window switch to do this! The drivers door controls will not operate that window without it.

I then reconnected the locking button and checked that the door locked OK and that global window close was also OK.

That's as far as I got today; refitting the door card and interior handle can wait for another day as the car is now secure and the main problem fixed.
I also intended to swap the rubber door seal over as the black shiny triangle is part of that and mine was in excellent condition, the replacement has a few marks.
Sadly that just seemed a bit too difficult so I didn't bother. I'll investigate another time; it may be possible to just take the triangle out and swap it, or more likely repair/repaint it.

The attached picture is the frame after I removed it from the car with glass still attached. You can just see that the top pulley is only the metal centre, missing it's outer nylon disc!
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__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!

Last edited by HPsauce; 25th September 2018 at 05:44 PM.
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  #36  
Old 25th September 2018, 04:51 PM
MikkiJayne MikkiJayne is offline
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I wonder if those pulleys could be printed...?
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  #37  
Old 25th September 2018, 04:54 PM
HPsauce HPsauce is offline
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I doubt it, they need to be pretty strong, especially the upper one!

And it's all riveted so replacing them isn't trivial.

I don't really understand why it's not metal, unless it's for noise reduction?
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!

Last edited by HPsauce; 25th September 2018 at 05:39 PM.
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  #38  
Old 26th September 2018, 05:12 PM
HPsauce HPsauce is offline
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Quote:
Originally Posted by HPsauce View Post
it may be possible to just take the triangle out and swap it, or more likely repair/repaint it.
And it isn't, it's moulded into the rather complex rubber seal, so I'll live with what I have for now.

Job finished but took a fair bit longer to fit the door card than expected.
When I came to investigate the clips etc. I noticed they were a mixture, some were the correct type (of which a couple broke) and the rest were a different design which didn't hold anything like as well, but were largely reusable.

So, someone had been in there before, and not used the right components.

A quick scout round found various bits disturbed, non-OEM wiring joins, duct tape in strange places and a strange label!
This label had some vaguely D2-related codes (but not valid part numbers) starting 4D0 899. It also had the magic word "NOKIA".
So something was once in there related to a mobile phone. Nearside rear door is a bit odd though...

Nothing surplus now, apart from duct tape and the label, but some foam bits were loose so I tidied it all up.

Final footnote. The repaired window is now the fastest to open and close.
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!

Last edited by HPsauce; 26th September 2018 at 05:15 PM.
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  #39  
Old 26th September 2018, 06:06 PM
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moltuae moltuae is offline
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Quote:
Originally Posted by HPsauce View Post

Final footnote. The repaired window is now the fastest to open and close.
Nice work. You'll no doubt be rushing to (preventively) fix the rest of the windows now so that they all open and close at the same speed

I wonder how easy it would be to make a mold of the plastic pulley and cast a new one from aluminium.
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  #40  
Old 26th September 2018, 07:14 PM
HPsauce HPsauce is offline
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Probably easier to do on a lathe, turn from a solid lump.

I'm going to look at my old one sometime and see what's involved in repairing it.
I doubt the exact size of the pulley is critical as long as it fits, it's just passive to take the cable round a corner.
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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