Home/ Repair guides/ 1994-1999 Subaru Legacy window bushing replacem…

Official iFixit API visual reference

1994-1999 Subaru Legacy window bushing replacement

This is a guide to replace the window bushings...

iFixit Library 1994-1999 Subaru Legacy Moderate 15 - 30 minutes Guide 175024

Licensed iFixit integration

This attributed iFixit guide is displayed through Fixonic's recorded commercial API permission. iFixit remains the independent source and author of the procedure.

Guide overview

Before you begin

This is a guide to replace the window bushings on a 1994-1999 Subaru Legacy window slide. From my searches, there weren’t any bushings being sold for this common issue in old Subaru windows so I took some measurements and made an .stl file on tinkercad. https://www.thingiverse.com/thing:670426... I hope this helps someone. Compared to replacing a full regulator it saves a ton of time and money. Note: If the window falls all the way down, make sure you get the plastic guide back onto the front most part of the window. It will likely have fallen down into the door. Your window will not function correctly without this plastic guide.

Step 1

3D print bushing

⌕

order bushings from ebay or measure and print with PETG using full infill: https://www.ebay.com/itm/146993090849

Step 2

Remove Door Panel

⌕

Remove door panel by following this guide: https://youtu.be/24MTC2Jd5uU
The process for removing the rear door is even easier.

Step 3

Remove Lower Rail from Window Regulator

⌕

Lower the window to 90% down.
Remove the two nuts connecting the rail to the window regulator. These nuts can be accessed through the hole in the door.
Once the nuts are off, remove the rail.

Step 4

Bend Rail to Accomodate Bushings

⌕

TOOL USED ON THIS STEP Small Crescent Wrench Referenced by the iFixit guide

View item

There is a tab bent into the rail on the rear-facing side to keep the bushings from sliding out.
Use the small crescent wrench to bend the edge of the rail until I could slide the bushings in and out.

Step 5

Install Bushings on the Regulator

⌕

Lower the regulator mechanism all the way.
Use channel locks to force the new bushings onto the window regulator.

Step 6

Repair step

⌕

TOOL USED ON THIS STEP Small Crescent Wrench Referenced by the iFixit guide

View item

Move the regulator up a bit to get enough clearance.
Slide the rail onto the new bushings.
Lower the regulator all the way down.
Use the small crescent wrench inside the door to bend the metal tab back up once the rail is in place on the regulator.

Step 7

Connect the Window to the Regulator

No step image supplied by iFixit.

Adjust the window regulator back to 90% down.
Line up the window bolts up with the holes in your freshly repaired regulator.
Reinstall the nuts securely.
Grease the rail where the bushings make contact.