I know there has been a lot of posts on this subject but I could find nothing on this particular issue. The power windows work just fine, however, when the drivers side is rolled all the way up, there is a loud "clunk" when the switch is activated to roll it down. And then just the opposite when the window is rolled all the way down, the "clunk" is heard on initial up motion. If the window is stopped mid stream either way (up or down) and then started again the same direction, the clunk is not heard. Has anyone experienced this? I could find a lot of info on the whole "power window regulator" thing, but nothing this specific.

 

Take the trim panel off and see whats loose. If it happens every time it should be easy to find.

 

Yeah... I got that far. I can't seem to find anything that is loose and other than the noise the window functions normally. There must be some sort of fastener (or something) that I can't see and was wondering if anyone someone more familiar with the inner workings of the door would know what it is. I guess I will have to get some mirrors

 

Yeah... I got that far. Other than the noise the window functions normally; tight seal, minimal rattle, good up and down speed. So inspecting the regulator and guide rails shows nothing out of the ordinary. I was just wondering if someone more familiar with the inner working of these doors would have an idea what it was. I guess I will have to get some mirrors and see what is going on in there. The noise is abrubt and loud enough that it scares the hell out of my passengers if I don't tell them it is coming.

 

Check where the reg. arm goes in the bottom slide. See if the plastic part is still there or if the arm has come out of the plastic and is just running in the track. And also check the fasteners for the regulator (rivets probably) see if they move when you go up or down. With the window at half way up if you grab it and pull up ... how much play is there?

 

What do inner door skins look like? Mine had a stress crack where the regulator mounted to it, caused the same type of noise. I had a friend weld on a fender washer and reinstall the rivet.

I have a picture of the stress crack, but misplaced the fix pic with the fender washer.

 

Well.... there is no stress crack, however, it seems one of the rivets holding the regulator in has loosened. I suppose I will replace it with a bolt. There is about a 1/4" of play when I pull the window up, so maybe one of the rollers has lost it's plastic "tire."

What a difference a good lube job did though. I wasn't really having any problems otherwise but after a good application of some white lithium the window works even better (and has lessened the clunk some).