Introduction
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.
What you need
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print bushings in PETG with full infill: https://www.thingiverse.com/thing:670426...
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If you don't have access to a 3D printer find a 3D printing service and order the part with the STL file.
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Remove door panel by following this guide: https://youtu.be/24MTC2Jd5uU
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The process for removing the rear door is even easier.
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Lower the window to 90% down.
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Remove the two nuts connecting the rail to the window regulator. These nuts can be accessed through the hole in the door.
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Once the nuts are off, remove the rail.
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There is a tab bent into the rail on the rear-facing side to keep the bushings from sliding out.
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Use the small crescent wrench to bend the edge of the rail until I could slide the bushings in and out.
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Lower the regulator mechanism all the way.
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Use channel locks to force the new bushings onto the window regulator.
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Adjust the window regulator back to 90% down.
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Line up the window bolts up with the holes in your freshly repaired regulator.
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Reinstall the nuts securely.
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Grease the rail where the bushings make contact.
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