Window Regulator Removal - Driver Side Rear

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo XC90s. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America).
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mre2000
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Joined: Thu Sep 14, 2017 2:03 pm
Year and Model: 2004 XC90
Location: Stockton, CA

Window Regulator Removal - Driver Side Rear

Post by mre2000 »

Trying to pull 2004 XC90 window regulator, drivers side rear assy. The motor is fine but the cable snapped. I've got three rivets removed from the bottom and a nut at the top of the assy. I HAVEN'T REMOVED THE SPEAKER (do I need to?). The window glass sits in an aluminum channel and this is where I'm hung up. It looks like two possibilities to separate glass from regulator assy but its not clear to me how its done. Have searched endlessly for drawings / pics / posts but cant find anything for this model and only info Ive seen is for completely different assys. Can anyone point me in the right direction or post link to instructions? TIA

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oragex
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Post by oragex »

Can't answer but a much easier way to go is to replace the whole door. I actually did so when I dented mine - same door as yours. It's easy although it takes two people to handle it back in place.

mre2000
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Joined: Thu Sep 14, 2017 2:03 pm
Year and Model: 2004 XC90
Location: Stockton, CA

Post by mre2000 »

Or, I can just replace the whole car. :)

Thanks but I just need to get the regulator out and cant see how to separate it from the glass.

joejoethedogfaceboy
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Post by joejoethedogfaceboy »

I did this exact repair a few years back and I’m trying my best to remember all the steps...

Are you talking about the aluminum channel at the bottom of the glass? That stays on the glass, and attaches to the window regulator via two rivets. I did remove the speaker, as I recall it made it easier to drill out the two rivets at the bottom of the glass.

Check this thread for more info: viewtopic.php?t=59256

-Joe
2012 XC60 3.2
2012 S60 T5
2004 XC90 2.5T (SOLD 11/2017)
1999 S70 GLT (24hrs of Lemons bound...)

mre2000
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Joined: Thu Sep 14, 2017 2:03 pm
Year and Model: 2004 XC90
Location: Stockton, CA

Post by mre2000 »

Thank you Joe, thats exactly what I'm referring to. I was hoping that was a square or torx bit but its another rivet? Crap. That clearly answers my question though so I'll be back on it this morning. Thanks again.

Cheers...
Mike

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Post by joejoethedogfaceboy »

I'll warn you that it's a pain to get the rivets out, and then even harder to get a new rivet back in there. You need a really long drill bit. IIRC, I ended up using a small nut and bolt in place of one of the rivets when putting it back together. (Don't forget the Loctite, if you go that route.)
2012 XC60 3.2
2012 S60 T5
2004 XC90 2.5T (SOLD 11/2017)
1999 S70 GLT (24hrs of Lemons bound...)

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