Thanks for your thoughtful reply. I'll insert responses/comments
between the lines of yours.
Absent a series of preceding problems the cable should not fray over
life of the car. Of course, in your case you do have preceding
Are you replacing the cable and pulley when you replace the regulator?
Yes, in each case, the whole regulator assembly was replaced which
includes the cable, pullies and the rigid parts.
Are you ensuring proper alignment of things inside the door? I've
inside the door so I really don't know if there are things you can
improperly install, but I have installed some regulators in my
The regulator assembly attaches to the door with 4 metric bolts that
look like about 1/4 inch diameter that are fixed to the regulator frame
and come through holes in the door and are affixed with 10mm nuts and
I'm assuming some standard stuff inside your doors. Gut intuition
you've got an alignment issue with the regulator.
There's very little movement through the holes in the door, so
alignment issues are almost non-existant. And, when the window goes up
and down smoothly and there are no air leaks, I'm quite sure the window
is aligned properly.
Do yourself a favor and stop by the dealer's body shop - or any good
shop that you may know of. Talk to the guys in there and describe what
you're experiencing. The dealer has the advantage of most likely
worked on other cars like yours and may be aware of some issues you
know about. Or - may be able to suggest something based solely on your
description of things. I'm sure they'll chat with you for no charge.
hurt. I do all of my own work on all of my vehicles and I've leveraged
experience of the dealers on many occasions. It might not even hurt to
the car to the dealer with the door panel removed already, and let the
guys have a look inside. Again - I'm sure they'll give you a few
for free and you might just discover the root cause of this problem.
I've done that too, and am told by my local dealer's bodyshop staff
that they experience this quite often on this model. It seems that the
plastic used in the pullies does not handle the high heat of the desert
very well (interior temps. in cars can easily exceed 200 degrees (F)
when the windows are up and summer temps. are in the 115 range...
Apparently Hyundai recognized this problem after 1998 and started using
a plastic that withstands high temperatures better.
Again, thanks for your helpful suggestions.