PeachParts Mercedes-Benz Forum - My W126 Window Jaw Replacement

Here is my experience replacing the broken slider jaw, modified method, on the rear window of a 1991 W126.
1. Picture of the broken assembly. The jaw has split in two.
http://i343.photobucket.com/albums/o...der_jaw-01.jpg

2. The broken jaw removed.
http://i343.photobucket.com/albums/o...der_jaw-02.jpg

3. Here is the list which consists of :
a. (1) Repair Jaw Assembly
b. (1) 5/16" ODx 1/4" ID bushing (I don’t remember the original length, I split mine in two for two bushings)
c. (1) 6mmx20 screw
d. (1) 6mm lock washer
e. (2) 6mm nuts
http://i343.photobucket.com/albums/o...der_jaw-03.jpg

4. Here is what I made in place of the rivet.
http://i343.photobucket.com/albums/o...der_jaw-04.jpg

5. In place of the rivet and flex washer (on right side) that comes with the repair kit I used a 6mm screw and bushing. In this picture you see the bushing as purchased. In needs to be cut to a length so that with the screw and bushing assembled in the jaw it is just slightly proud of the boss feature on the plastic.
http://i343.photobucket.com/albums/o...der_jaw-05.jpg

6. Grind the rivet from the lift arm. Clean the track out where the slider resides and re-lubricate. Get the new jaw in the slide can be a real pain. You need to squeeze it top to bottom and press the back snap in plate at the same time. You will think that it will never go in and have thoughts of using big saws and grinders…don’t. Just try and try. Once you have it in the track have a drink and take a breather because you are almost there (excluding step 8).
http://i343.photobucket.com/albums/o...der_jaw-06.jpg

7. Next simply put the end of the screw thought the rivet hole on the lift arm and fasten the lock washer and final nut. (Sorry for the fuzzy picture. I will never make movies as I would like to do)
http://i343.photobucket.com/albums/o...der_jaw-07.jpg

8. The final step is the worst…..putting that @#$%@#$%@ door panel back on. I hate this hook design. The W123 door panel attachment is perfection; the W126 is from hell. My worst part was getting the hooks and door light wires to all work together. After two hours of cursing and desiring to burn this car in the street I removed the door light wires from the retaining clip and rerouted them. Viola now everything worked in going together.
Side note: As much as I like my 300SE by comparison a W123 is a breeze to work on and much more trustworthy.