2004 Malibu Power Window regulator cable issues

[papagary]

I have a 2004 Malibu LS with approximately 65,000 miles. It is my wife car that she uses to and from work which is about 2.5 mile a day total. I have gone through 6 window regulators assemblies where the cable has derailed from assembly over the last 6 year (4 drivers rear, drive front, and passenger rear.) One seems to go bad every 1.5 to 2 years.

Dealer and other mechanic have said that it is just easier to replace the entire assembly. I have replaced 3 myself and the other 3 by the dealer. Sure enough, it just happened again and now I am looking to get the drivers rear replaced again.

Since the car rear window are very seldom used, what might be causing the cable to derail on occasional use?
Is this a common problem?
Is there a cable free system that I can purchase?

Any feedback is welcomed, Thanks.

 

[zora]

are you using original GM parts when you replace them?
could lack of use be the issue, is there any signs of corrosion on the units you have replaced?

 

[papagary]

Thank you for replying to this issue.

3 of the installs has been done by the dealer which I am assuming were GM parts. Since they have a 1 year warranty they would not cover the problem. The other 3 that I replaced were AC Delco and Doorman manufacture.

I live in central California where it is very dry and hot, no signs of rust. The pulleys on the unit seem to move freely.

I don't know if there are any limit switches that could be bad?
Could the door frame be bent slightly causing the issue?

 

[zora]

I would suspect if the door frame was bent you would see the windows binding as they went up and down. The only other suggestion I could find was periodically lubricating the felt channels with silicone spray. See if they do anything different in this install video.
https://www.youtube.com/watch?v=ZEmvjrnoEpk

 

[papagary]

I ordered a doorman window regulator since the dealer here uses AC Delco parts.
I will be sure to lubricate the felt channels as you mentioned.

Thank you for the video and the lubrication advice.

I contacted a window regulator refurbishing company in Phoenix that works on high end cars and this is what they had to say:

"The current OEM parts are not the same as the original OEM parts. The current OEM parts along with other after market window regulators are made of more plastic and lighter metal which compromising the unit. If the car sits in high temperatures (Which mine does), the plastic can be effected causing it to malfunction."

This makes sense in my case since the door that is going on its 4th regulator in 10 year gets direct sunshine everyday for most of the year.

Thanks for all of the support.

 

[zora]

I could see high heat on a daily basis contribute to plastic component parts failure. Good luck.