2002-2006 sprinter van window lift guide

thingiverse

My 2006 Itasca RV (Sprinter Van Chassis) had the common driver's window issue this weekend reported by many. The driver's (or passenger) window falls off the track at the bottom of the travel. The cause is the plastic window guide becomes brittle and splits in half allowing the lift rod pin to fall out of the guide rail and drop the window. The official fix is to replace the entire lift assembly for $300. I designed this modification to replace the broken plastic guide. It uses the remaining guide pin and simply slides over the pin head. This first rev attempts to improve the strength of the guide to prevent the splitting seen in the OEM part...but time will tell. This mod should work on 2002-2006 Sprinters and possibly more applications. Install takes 10 min or less. Remove the door card and power switches to gain access to the window and lift mechanism. Youtube has many videos Raise the window lift rod using the power switch (temporarily plug the switch in) to where the window would be half way up. Carefully lift the window glass up by hand. Clean the rail of old grease and remove the broken plastic guide if needed. Lubricate the guide rail with white lithium grease. Slide the new guide into the rail and insert the lift rod pin head into the guide. Use the power switch to run the window up and down several times to spread the grease and confirm the fix. Reinstall the door card and switches.