After reading a number of threads about the nylon plugs in power window gears I did a repair that went South BIG TIME. Instead of the nylon plugs I installed a set of .500" ball bearings. This was a huge mistake. All was well, until I installed the window glass and rolled it up to the top.

As soon as it hit the top the gears tried to slip and BAM. The window was once again loose and could be pushed down by hand. I took everything back apart and discovered the plastic gear had SHATTERED.

After seeing this I now understand why the nylon plugs. They "give" and allow the gear to slip in the event the window is rolled up or down too far. If you accidentally hold the button down for a split second too long the gears slip, hence the noise you hear. repeatedly doing this is what chews up the nylon plugs.

If you replace the nylon with metal the only thing left to "give" is the large plastic gear. I hope this answers the "What if I use bearings" question on one of the threads in this forum.

The nylon plugs are less that $7 at Autozone, far less than the 25 bucks I shelled out to replace the gears. The plugs are on the HELP rack Part #74410

wow thanks for this input, I was just getting ready to do this on 2 doors I have and was planning 45 cents a piece for the ball bearings. I will follow your advice, it makes since, especially if you have little kids that continuously hold the button down while they are spaced out in wherever land.

That's interesting. Before I knew about the replacement nylon plugs I had put in a few nuts and never had a problem, although this was in older cars, like a 77 Lincoln so maybe there was something different about them. Either way, the rebuilt kit that is available for most power windows is a good thing. :-)

Yeah the nylon plugs were well thought out. I even tried a few types of hard rubber. They didnt last more than a month.

Ebay is the cheapest i have found so far

Thanks for confirming what I've been trying to tell my Dad. My drivers side window stoped going up or down so he put in Metal berrings. Well, only 3 days later it stoped again. So, this time, I kept my mouth shut and replaced it all with the nylon replacements. All is good 2 years later.

I have the same problem with the my dad's explorer, his windows come down if you push them down. How easy is it to replace? I've never seen this or replaced them before so I have no idea where to start. Thanks for the help.

...This thread will help..;)
http://www.explorerforum.com/forums/showthread.php?t=145469

Great write up! Thanks.