996 Driver's side window not closing properly when door closed

[Mark44]

I posted another thread recently about a broken door spring on the inside door handle of my '02 996 coupe. I replaced that spring successfully and thought I had taken care of the problem with the window not clearing the gasket when the door is closed.

It turns out that the problem still exists. When I made that repair, I had the battery disconnected so as to prevent the airbag from firing. After putting the door panel together and connecting the battery, I went through the procedure of holding down the window button to recalibrate the motor, and the window seemed to be working as it should. However, the problem still exists.

I've looked at the Berkeley book and the 101 Projects for 996 books but am not able to find any information on this problem. Both the window motor and regulator seem to work smoothly, with no weird noises.

Is there a sensor of some kind in the window regulator mechanism that could be operating intermittently? Note that the window goes up and down as it should, and the window drops down 1/4" or so when the door is shut about half the time, so it isn't like some component has failed completely (which would make diagnosis easier).

[Mark44]

Bump...

[JFP in PA]

Bumping is considered rude.

You have a problem with one (or more) of the micro switches in the door.

[Mark44]

Thanks! That gives me an idea of a path to take to fix this problem.

[Van B.]

Have you held the window switch while you rolled the window all the way down and then all the way back up? Sometimes the windows and sunroof need to be relearned by the ECU.

[Mark44]

Originally Posted by Van B.

Have you held the window switch while you rolled the window all the way down and then all the way back up? Sometimes the windows and sunroof need to be relearned by the ECU.

Yes, I have done that several times, to recalibrate the mechanism. It seems to help for a time or two, but the effect doesn't last.

When you pull either the inside or outside door handle, the window drops the required amount. When I shut the door from outside, the window seems to work correctly most of the time, but when I'm in the car and shut the door, the window often doesn't clear the body gasket.

I've posted a comment on the 996 Project List section, but I don't see my comment yet. Maybe the Pelican folks are mulling it over before responding.

So my question remains: Is this a problem with the regulator or is it in the window microswitch assembly?

[Van B.]

You may need to pull the door card and look for loose or broken things in the window assembly. Unusual for that feature to work intermittently. Seems more likely the feature is working but the mechanism isn’t right.
Is there a moment when you roll it up and down when you hear the motor, but the window lags for a fraction of time?

[Mark44]

Originally Posted by Van B.

You may need to pull the door card and look for loose or broken things in the window assembly. Unusual for that feature to work intermittently. Seems more likely the feature is working but the mechanism isn’t right.

Right, that's my thought. I've had the door card off already, to replace a broken inside door pull spring, but didn't see anything that looked out of whack. After I put the door back together, I still had the problem of the window often not clearing the door frame gasket.

Originally Posted by Van B.

Is there a moment when you roll it up and down when you hear the motor, but the window lags for a fraction of time?

No, there aren't any lags and no weird noises.

[Van B.]

Well I have nothing else. Strange to me that you only have the problem when closing from the inside.

[Mark44]

It's not exclusively when I shut the door from inside the car. When I'm outside the car the window sometimes hangs up, but it seems like less often than when I'm inside pulling the door shut.

[Van B.]

Well, I had a couple ideas outside of what JFP suggested, but the man knows his stuff so, I would follow his advice.

[Mark44]

Originally Posted by JFP in PA

Bumping is considered rude.

Which is why I waited for five days before bumping my post.

Originally Posted by JFP in PA

You have a problem with one (or more) of the micro switches in the door.

Thanks for the tip. I'll order the microswitch set and see if that does the trick.

[Mark44]

Originally Posted by JFP in PA

You have a problem with one (or more) of the micro switches in the door.

I have replaced the microswitch that is attached to the outer door pull with a new one from Pelican, but the window is still not working right. I have the Berkeley book for 996/997 Carreras, and have just reread the section on door windows. If there is another microswitch in there, I didn't see it mentioned.

As I understand how the window mechanism is supposed to work, when you open the door, the window is supposed to drop down 1/4" or so, and stay there. Then when you shut the door, the window will clear the door seal, and then go up the last 1/4". My driver's side window does this only intermittently. At least half the time, the window will drop like it's supposed to, but then go back up when you release the door handle, either the inside or outside handle. This is the behavior of my passenger-side window.

Here are all of the symptoms and information I can think of:

• The window goes up and down via the console switch with no unusual noise or jerky motions. This suggests to me that the problem isn't with the regulator or window motor.
• When you pull on either the inside or outside door handle, the window drops its 1/4", but letting go of the handle causes it to rise back up again. As already stated, the problem seems to be that it doesn't stay down every time, causing the window to hang up on the door seal.
• The previous owner ran into a deer, causing extensive damage to the front of the car. As far as I know, that damage didn't extend to the doors.
• The spring that keeps the inside door handle taut broke, but I have replaced this spring. I believe I have installed it correctly, based on the witness marks left by the broken spring.

If anyone has any ideas, I would be very thankful.

I will also post this on the Pelican Tech Support page.

[Paul C Roddy]

Hello Mark44 - My 03 C4S had the same issue. A door lock mechanism was the required fix.
https://www.pelicanparts.com/More_Info/9A783701503OEM.htm?pn=9A7-837-015-03-OEM&bt=Y&fs=0&SVSVSI=4878

[Mark44]

Originally Posted by Paul C Roddy

Hello Mark44 - My 03 C4S had the same issue. A door lock mechanism was the required fix.
https://www.pelicanparts.com/More_Info/9A783701503OEM.htm?pn=9A7-837-015-03-OEM&bt=Y&fs=0&SVSVSI=4878

Thanks, Paul! I appreciate your response and will look into this.

[Mark44]

After digging into the driver's side door three times, my window now works as it should. Thank you to Paul C Roddy and Van B. and JFP in PA for their suggestions.
To be honest only two of the three expeditions into the door were to fix the problem with the window not clearing the door gasket: the first foray was to replace a broken spring between the inside door handle and the latch mechanism.
Replacing the wire that has a microswitch at the end did not solve the problem, but replacing the door lock mechanism finally did the trick. The most difficult part of this process is connecting the link from the outer door handle to the L-shaped plastic part on the lock mechanism. It's way back in there, in a very confined space. I had to get both arms in there to join these pieces, and it took me at least an hour to do.

[Van B.]

That’s really good info!
Thanks for posting up the fix!

[Paul C Roddy]

I have to admit I attempted a DIY and backed out of it and I ended up having it installed. I admire your patience.