So I just bought a 02 cooper with a broken passenger side window motor. I am following this DIY: http://www.z50ak1.com/mini/default.htm

I feel kind of stupid cause I'm stuck at the part where you have to remove de window. I got the sprockets loose but can't get to remove them as there is not enough space as a result the window is quite loose but I can't remove it! It is so frustrating... anyone can help? If I could just roll the window donw a bit to clear that kind of bump inside the upper part of the door I could easily remove them!

I just switched from a miata to this and I tell you, this is a bad first experience at working on a German car

 

I feel your pain. Been there done that. You say the motor is 'broken.' In my experience, if you jostle it often enough, turn the power on and off, manually gently pull the window up and push it down, and thump on the inner door skin above the speaker, eventually the motor will work again. This will permit you to lower the window far enough to access the star-headed bolts that connect the glass to the regulator. Good luck.

 

Window motor replacement requires a *special tool*...trying to fit any tools between the door and glass often results in a broken window...

 

The special tool is only required if the window is at the top and can not be lowered; otherwise, a 5 mm or 3/16" allen wrench works.

 

Yeah I guess the guy who wrote the DIY assumes the motor is still working ha! Anyway I got everything off by removing the rails and prying like crazy.

Anyone has a picture of the special tool? I could get my friend who's studying to be a machinist to make me one.

 

removed door panel (easy). used torx driver to remove four screws holding motor onto actuator. (somewhat easy) THEN....the commutator springs and brushes pop out....but, once you get it back together, and test the motor....it works just fine....WELL....just try putting the little bugger back in!! The helical drive shaft just doesn't line up, the cables pop off the pulleys, and by the way, you really can't see inside the door unless you are a hamster. (my hands still have the battle scar srapes and cuts to prove it.)

I had a lot of clear lubricant/oil on my driver's window after purchase in 2002...reappeared when window was lowered/raised,,,,for about the first month. Then went away...then motor failed (under warranty). 3 years later, failed again.....TRUST ME...I change my own oil, brakes, spark plugs, filters, etc., etc.....but trying to pull out that actuator is a real !@#$%$@!!!

The dealer really doesn't want to install just an actuator or a motor...it comes from Mini as a complete unit. Have the dealer do it....it's worth the $500....but be sure they check the alignment of the guide rails in the door that the window travels on, as they are tending to jam up the windows and prematurely wear out the motors....that's why some folks are writing in that "hitting the door panel...hard...makes it work again...well, that is because it is jamming on the internal rails. Evidently, Mini tries to over-lubricate the rails to try to compensate for this design issue (ergo...the excess oil).