Reviving the Roll: 3D Printing a Replacement Power Window Gear

When the 30-year-old plastic inside your power window motor finally gives up the ghost, it’s the perfect opportunity to fire up the 3D printer. Let’s fix that annoying window click by printing a fresh, durable replacement gear.

The Problem

Decades of stress and heat eventually cause the original plastic gears inside the window winder assembly to crack and break. Instead of trying to track down a rare replacement motor, we can design and print a better-than-OEM piece.

Preparing the Print

• Material Choice: PETG or Nylon is highly recommended due to the high temperatures inside car doors during the summer. Standard PLA will warp.
• Infill: 100% solid infill for maximum strength.

Reassembly

With your new gear printed, gather your tools and get ready for the install. You’ll need a hammer, some fresh grease or Vaseline to keep the new gear lubricated, and maybe a cold beer to celebrate a successful print!

After cleaning out the old, brittle plastic shards from the motor housing and greasing everything up nicely, you can finally tap your tough new 3D printed gear onto the assembly.