First off, thanks to everyone who has contributed to this thread. This is one of the best "how-to" threads that I've ever seen in any forum!
Short story: Got the Cardone 42-96 gear and plug replacement kit at O'Reilly Auto Parts. $17.99 + $2.00 core charge.
There was so little gear plug material left in the gear section of the motor that I felt it was necessary to remove the four torx screws and try to remove the worm gear. Boy howdy, was I ever surprised when those springs and brushes popped out. After I'd cleaned the cavities in the motor housing that weren't reachable with the worm gear in place I put everything back together.
Yup, I spent over two hours getting those brushes and springs back in place by using two small screw drivers. I was wishing for a third hand! Anyway, got the motor back together, gears greased, C clip on and reinstalled on the driver's door. Things are definitely looking up.
Then came the time we all look forward to with hope and trepidation. I pressed the up button on the window switch and the window rolled down. What the ????
Then I pressed the down button and the window rolled up!
I've gone over the disassembly and reassembly of the motor in my mind and can't think of any way that I could have reversed the polarity of the motor. (If that is even the right way to describe the problem) It seems that everything can only go back in one way. The wires that hold the brushes will only allow each brush to be assembled in one spot. The springs that press against the brushes have no effect on motor direction. The motor housing (would this more correctly be called the armature cover?) seemed to be mounted correctly. I'm not sure that it could be spun 180 degrees from the way it was originally mounted. At this point I'm not taking the motor apart to look.
Finally, the power connector to the motor can only be assembled one way. So how on earth could I have reversed the direction that this motor spins?
Thanks in advance for any insight you can offer!
Chris Glennon
Roswell, GA
Just went to the O'Reilly Auto Parts site and noticed that a 42-91 kit is available in addition to the 42-96 kit. The 42-91 kit has a white large 45 tooth gear while the 42-96 kit has a black 62 tooth large gear. The original gear in the motor was white. I noticed the color difference when swapping out the gears but wasn't too concerned about it. I've already returned the core for the refund. Should I have used the 45 tooth white gear 42-91 kit? If so, is there any way that using the different gear would have any affect on the direction the window travels vis a vis the switch?