Here we go again...
Back on the job, and pulled the right door panel this morning, to take a look at the passenger window problem....
The part is cheap, about 5 bucks from JAE, the time to change it, probably way too much, the entire regulator may have to come out if the part does not snap in the rail, and may have to come out anyway.
My biggest concern is the root of the problem, the grease. Outdoors here today the high will be 37 degrees. The garage is non heated, but well insulated, and I expect it is close to 50 degrees. The grease at that temp feels like some cheap grease mixed with horse glue and honey. The broken plastic parts do not 'slide', only moving with a bunch of pressure, and would guess that is what caused the block to be pulled apart. That is probably what could have also perhaps caused excessive wear in the ball socket of the plastic block, but have not verified that there is actually wear there until it is out. The grease must be at least causing a 4x current draw on the lift motors.
These types of problems really irk me. The factory, or whoever built the lift assembly used a grease that either does not age well, or is not intended for any kind of cold weather. It would be better suited to be an adhesive. Maybe they were trying to make it sticky to help reduce rattles, who knows, but I am not the least impressed that Lotus Engineering failed so bad in this case of grease selection.
It is so bad, guess I will also be pulling down the drivers side door too, and striping the grease out of the window and secondary rails and replacing it with mobil 1 synthetic grease. Maybe then the window lift motors will continue to survive. No wonder so many motors, switches, relays and such fail. I would bet this grease deal causes at lest 80% of all window related problems.
I would expect this problem also presents itself on many, if not all esprits, and am sure I am not the first to discover it.
It does not take a few ounces of pressure to move the plastic block parts, but quite a bit of force.