'92 LeSabre Limited - how to fix driver window regulator

Howdy! Window rolls down about 50% or 60%, then starts 'hammering' as if a large gear is butting up (stripped). Luckily, the window can be grabbed and lifted and will re-engage, but I can't count on that lasting forever...

Can't find any source for a new regulator or parts for one. I haven't pulled it yet, so I'm wondering how it's put together and whether maybe there are plastic shoes, cogs, or something that could be reproduced with a 3D printer?

The 26-year-old car is an 89K-mile cream puff, but this makes it troublesome to transact my fast-food purchases... :) Thanks;

Gregg

https://www.rockauto.com/en/catalog/buick,1992,lesabre,3.8l+v6,1019607,interior,window +motor,1516
There are others selling this online. Just google it.

YouTube has videos.

Thanks for responding, aleekat;

I was wondering what was so special about '92 regulators ('91-'96, actually) that nobody had made a replacement, and expected something like the 2000 Grand Am I came across years ago which had nylon shoes(?) that snapped onto a cable, got old, fatigued and broke when the car was less than six years old.


Took me a while to find out what I had in store; the factory Electrical Systems Manual had motor replacement but nothing else...I finally looked in the Service Manual (Body chapter) and found the rest of the door component procedures. No more Fisher Body Manuals, I guess.

The regulator, which looks conventional, is built onto what's called a door module (and no aftermarket company is likely to want to stamp those things out)...It's nice to at least have an idea what's waiting for me.

Thanks for the input;

Gregg

You may be down to the option of salvage yard parts or repairing your sector gear, like this:

http://www.wwdsltd.com/files/RegulatorGearTeethMissing.jpg


http://www.wwdsltd.com/files/RegulatorToothWelding.jpg


http://www.wwdsltd.com/files/RegulatorToothShaping.jpg


http://www.wwdsltd.com/files/RegulatorTeethRepaired02.jpg

I'll bet you're right, Blue Bowtie - nice pics of nice work, BTW;

I wonder how two missing teeth translate to vertical travel; I have about eleven inches' worth if I shove the glass all the way down, and then pull up until it reengages...

Gregg

Your regulator may not be stripped, but just bent. Unfortunately, there is only one way to determine that, and when you're in that far...

...and when you're in that far...
...Agreed.

I'll bet you're right, Blue Bowtie - nice pics of nice work, BTW;

I wonder how two missing teeth translate to vertical travel; I have about eleven inches' worth if I shove the glass all the way down, and then pull up until it reengages...

Gregg

Once you hit the missing teeth, it just spins in place.