XR8 XR6 Club of Victoria
Join Date: Nov 2001
Location: Melbourne, Australia
Sounds like you need a new regulator.
The regulator assembly is not repairable unfortunately.
The unit is around $200.
Don't bother getting one from the wreckers as they generally charge $120 to $175 and may not last.
They are not hard to change over. The most difficult bit is the pop rivets that secure the motor unit and bolting up one of the motor mount flanges.
Use a hammer to gently tap the pin in the middle of the rivet into the inside of the door. Then use a 1/4" drill bit to drill out the rivet.
Use 5mm or 6mm bolts (10 or 12 mm long) and nuts (nuts should be nylock or shake-proof types) to secure the new assembly.
Note that one of the flanges is very close to the motor. I bend this one outwards, insert one of the bolts through and bend the flange back. The thread ends up coming through the door panel and there is enough room behind the flange to insert a spanner.
Rivets are much easier is you could borrow the correct size rivetter. New pop rivets are available from Ford spares (@ $1 each) but one would need a 1/4" rivetter and these cost $80 for an el-cheapo and around $200-$300 for a good tool.
I've done a few of these and it takes about 30 minutes to do the job.
The XR family ---->
Muzza: a XR8 AU seriesIII...bog standard :)
TBH: (the better half) drives an ED XR6 wagon (Mock Dev 4 160rwkw, JMM extractors, 4 electric windows, Ghia door panels in XR trim, rear head & arm rests in XR trim, Momo s/wheel with Cruise, EL thermos, EBGT wheels, etc) things to come soon = EECV upgrade.